THE VISIT OF MANUFACTURING PROCESS STUDENTS TO SIRIM 2012

On the 17th February 2012, the students of manufacturing process class held up a visit to Standards and Industrial Research Institute of Malaysia (SIRIM) center which is located at Bukit Jalil, Selangor. This study tour was organized by our lecturer, Ms. Jaisatia. It is estimated around 30 students took part in this trip, with a transportation aid of 2 buses. The journey to the Bukit Jalil centre was a hour and a half ride. Its easy to spot the SIRIM centre once we are in the Bukit Jalil vicinity, as the Bukit Jalil National Sports Complex serves as a landmark. Upon arriving there, we are greeted by some officers working at SIRIM. It was an official gesture, as this was a study trip. They then lead us to the pantry and we are served with some local delicacy. Once we are done with the morning dine, we are guided to the very first department, which was the rapid prototyping center. It was a nice introduction to this sector, as the display of various things designed from this branch was on display in a showcase. Well, at first, we are divided into three small groups, and are designated to the officers involved. They will serve as a guide for the respective groups, hence giving us a brief explanation about the machines used in this department. Its certainly a home for some high tech gadgets, with machines such as SLA 7000 System and FDM 400mc in store. Furthermore, the detailed explanation and the expertise of the officers involved certainly turns up the excitement. Once we are done with this department, we are then lead into the conference room, which our lecturers companied us as well. At here, we are given a briefing based on power point presentation that was prepared by Victor Devdass. He is the head of design engineering in SIRIM. Well the slides were mainly about SIRIMs product design and engineering centre. It was a student friendly presentation as we are given briefing ala class room situation, and also given a chance to shoot out questions in order to clear our doubts. The tour then continued to the bio modeling and fabrication center. At here we are exposed to the fabrication of human body parts. Its certainly a breath taking technology as we can redesign a body structure from a scratch. Well, the pin point accuracy certainly adds another amusement factor. The working space for this branch is much smaller than the rapid prototyping site as this branch was mainly computerized designing and rapid prototyping is about production. The last round of visit was to the reverse engineering room. At there, we are greeted by the officer in charge and he gave us a guide about the reverse engineering process. It may be simple to the views of naked eyes, but then it certainly takes a high patience and the skills to perform this process. We are also given a handy information regarding the equipment used, that is ATOS 3D scanner. Well, with a price tag of RM 800000, this device certainly lives up to the job. A short photo session with the SIRIM representatives followed up in the lobby, and then we all boarded the bus for a safe journey back to Unisel.

Well once we have returner to our home ground, we have done a research on the history of SIRIM. From our research, we found that the moment stars on September 1975, where Standards and Industrial Research Institute of Malaysia (SIRIM) was established. Its more of a combination between Standards Institution of Malaysia (SIM) and National Institute for Scientific and Industrial Research (NISIR). From here, SIRIM is classified as a statutory body under the Ministry of Science, Technology and Environment Malaysia. Furthermore, this organization is governed by the SIRIM Council. There were major events that took along the timeline of SIRIM. The first was on July 1993, where SIRIM Act was amended, thus enabling SIRIM to operate as a contract research organization, and also to establish joint ventures and subsidiaries. As the timelines continues to tick, on November 1996 SIRIM Berhad was incorporated. After some period of time, on September 1996 SIRIM Berhad came into operation. This will serve as a successor company to the Standards and Industrial Research Institute of Malaysia under the Standards Act 1996. The purpose of SIRIM is to promote and undertake scientific industrial research. Furthermore, it serves as a booster for industrial efficiency. Never the less, the corporation also have the function to provide technology transfer and consultancy service, which means that it provide community service which help the Malaysian people to do work more efficiently and in rhe correct platform. Besides that, SIRIM also develops Malaysian standards and also promotes standardization assurance for greater competitiveness and also a better quality. Another functional purpose of SIRIM is that it enhances the public and industrial welfare, health and safety. The visit to SIRIM has enable us to gain knowledge on several machines. This machines are those used in by the SIRIM organization to perform several task. Among the machines that came into view was the SLA-7000 stereo lithography machine, the vacuum casting machine, Fused Deposition Modeling 400mc machine, and the ATOS 3D scanner. Well the officers in charge has out load a lot of valuable information about this machines that are in use. We have note down those information are detailed in the following page.

The SLA 7000 stereo lithography machine, is also known as a 3D printing, optical fabrication, photo-solidification, solid free-form fabrication and solid imaging. It is an additive manufacturing technology. The main use of this machine is for producing models, prototypes, patterns, and production parts. Well the following is a brief point on the process of handling this machine. The process were actually explained by the officer involved. The process of handling the SLA 7000 stereo lithography machine is:

Enter the CAD data

STL file which is used to detect the surface

Create the support

Enter the material in to the machine

Run the machine

For every matter, there always the pros n cons. Well the advantage and disadvantage of the SLA7000 are as follow:

Advantage Speed which functional parts can be manufactured as shortly as within a day. A much smoother finish. Very high accuracy.

Disadvantage This machine requires cleaning process. Its very costly, expensive. For a flawless performance, the machine requires a low humidity place. The machine has limitation in terms of materials that can be used. The maintenance cost for this machine is expensive.

The Fused Deposition Modeling 400mc machine is an extruder device that builds the given specimen layer by layer. Well, in simple tense, the melted material is deposited by the extruder, then it cools, bonds and get hardens. Hence, the object is formed. Well the FDM 400mc mostly uses Acrylonitrile Butadiene Styrene (ABS) and Polycarbonate (PC) as the materials to do this process. It is understood that these materials are more reliable and can adapt with the machine. Well the following is a brief point on the process of handling this machine. The process were actually explained by the officer involved. The process of handling the Fused Deposition Modeling 400mc is:

The first step in this machine is uploading the STL file for a rapid quote

The machine will transform the CAD drawings into plastic parts

The parts are built layer by layer in an additive process

Extrusion heads lay down thermoplastics to create each layer

Finally the product is completed

For every matter, there always the pros n cons. Well the advantage and disadvantage of the Fused Deposition Modeling 400mc are as follow:

Advantage The product can be directly used it doesnt require cleaning process. This machine can withstand higher temperature. This machine also can build as many parts as you require. The machine also has higher accuracy.

Disadvantage The nozzle of the machine must be cleaned after each layering. The machine are quit slow Poor surface finish The support design and removal is difficult.

Vacuum Casting is a time saving and cheaper prototyping method for producing small numbers of highly accurate polyurethane prototype parts. These products has the characteristics and quality that are comparable to the final product. Well these characteristics will suit the purpose of functional testing or for marketing purpose. Well the following is a brief point on the process of handling this machine. The process were actually explained by the officer involved. The process of handling the Vacuum Casting: The first step is to produce a pattern using any of the available RP processes. The pattern is fit with a casting gate and set up on the parting line, and then suspended in a mould casting frame. Once the two-part silicone-rubber is de-aerated and then mixed, it is poured into the mould casting frame around the pattern. The mould is cured inside a heating chamber. The pattern is removed from the silicone mould by cutting along the parting line. The urethane resin is measured, dye is added for colored components and casting funnels placed. Then, the mould is closed and sealed. The computer-controlled equipment mixes and pour the resin inside the vacuum chamber. Because this takes place in a vacuum, the mould is filled completely without leaving any air pockets or voids. After casting the resin, the mould is moved to the heating chamber for two to four hours to cure the urethane part. After hardening, the casting is removed from the silicone mould. The gate and risers are cut off to make an exact copy of the pattern. If required, the component can be painted or plated.

For every matter, there always the pros n cons. Well the advantage and disadvantage of Vacuum Casting are as follow: Advantage Large amount of material varieties available for processing. Fast and hence, time saving. High quality surface finishing. Special effects like insect molding. Disadvantage The machine cannot create many product at a time. The machine cannot cast actual material. Very thin wall sections are not recommended and chances of cracking or warping.

The ATOS 3D scanner from the series of industrial optical 3D scanners provides accurate scans with detailed resolution at high speeds. ATOS enables the three-dimensional measurement data and analysis for industrial components such as sheet metal parts, tools and dies, turbine blades, prototypes, injection molded parts, castings, and more. Rather than measuring single points or with a laser, ATOS captures an object's full surface geometry and primitives precisely in a dense point cloud or polygon mesh. Well the following is a brief point on the process of handling this machine. The process were actually explained by the officer involved. The process of handling the ATOS 3D scanner

The machine is turned on

The product is then marked with several points called reference point

The picture is captured

The picture is then send to the computer

The product is then ready to use in any software such as AutoCAD. : For every matter, there always the pros n cons. Well the advantage and disadvantage of ATOSS 3D scanner are as follow: Advantage Highly accurate 3D measurements. Detailed, high-resolution scans. Quick data collection. Disadvantage Expensive The process depends on the size of the product The machine require a skill full operator to move the probe to each location on the part to take a measurement.

Advanced inspection functionality.

Not to be forgotten, we also visited the bio modeling centre. Well there was no equipment that came into view here, other than computers. But yet, they provide us with some valuable input. A brief explanation on bio modeling : Bio modeling is an art in a very own way. Its a very delicate reconstructive process. These is because every patient's requirements are different, unique and specific to the individual, and every procedure involves parts with their own distinctive shapes and configurations. Well, surgeons are constantly being challenged to treat patients in ways that minimize the destruction of human tissue and yet offer aesthetically-pleasing results. Good news for them, modern technologies now allow doctors to employ imaging techniques such as Magnetic Resonance Imaging (MRI) and Computerized Axial Tomography (CAT) to scan patients' deformities without performing any bodily incisions. From here, SIRIM can use this data to produce accurate plastic models of the deformities and design biomedical craniofacial implants that accurately fit the needs and requirements of each individual patient. So as a silver lining, doctors can also use the models to plan their surgery, thus minimizing the risks of patients who require extensive reconstructive therapy. For every matter, there always the pros n cons. Well the advantage and disadvantage of BIO modeling are as follow: Advantage
Reduce the operation time of an surgeon or doctor. Can do basic planning for the patients. Expensive Slow

Disadvantage
After the all process will leave some waste product.

As a conclusion, the trip to SIRIM has given us a lot of information. It gives us a tutorial journey that the modern world has to offer. Never the less, the expertise of the officers has inspire us to be like them, or even better. It requires hard work and indulging the right skill, but nothing is impossible when it comes to human achievement. We would like to express our greatest gratitude to Miss Jaisatia for giving us this opportunity, a very valuable experience for us as a engineering students of Unisel.