Xerox
 Stereolithography makes a strategic difference at Xerox by
helping designers muffle copier noise. With its SLA systems, Xerox works within budget and on schedule more
easily and efficiently, consistently meeting design objectives.
The Challenge
What do cars and copiers have in common? Why, mufflers, of course! Design engineers of
both automobiles and copy machines need to integrate muffler/cleaner assemblies into
their products. You create noise when you drive down the road and when you run three copies of your memo.
To reduce this copier noise, air turbulence must be controlled. This was a core objective
for Rob Kendall, model maker in Xerox's rapid prototyping lab. Stereolithography (SL)
was key to rapid prototype generation of their new copier's muffler assembly design.
The Results
To simulate sectioning of production parts from the silicone mold process, the center
muffler component was built in two pieces using stereolithography, then bonded together with SL material.
This project exemplifies how SL lends itself to fast multiple iterations for design optimization. A third assembly component
destined to hold a charcoal ozone filter was also constructed in the SL. The design shown was later modified to
incorporate an air duct and then rebuilt on the SLA system.
The final designs for each of these components were built using SL as patterns for silicone molding. This process
allowed Xerox to create the optimal design comfortably within budget and schedule constraints.
Xerox has found that stereolithography boosts their competitive position in a number of areas:
- Confirms manufacturability of assemblies
- Fast, easy, low cost method for testing new, innovative design ideas
- Saves money by form and fit testing to confirm assembles before investing in
costly tooling
- Quick turnaround on multiple copies of patterns for silicone molding
- Provides aid in vendor relations, insuring a bid on the exact design SL parts are
utilized in functioning copiers until production parts become available
The Process
The design drawings originated from a Xerox project group, which used Intergraph
wireframes to represent the assembly. The files were sent to the rapid prototyping lab where the wire-frame reference
file was converted to solids using Intergraph's Engineering Modeling System (EMS).
"Because of stereolithography, our future products at Xerox will be of higher quality and
lower cost."
- Rob Kendall, Model Maker
Rapid Prototyping Lab
Xerox Corp
Rob took advantage of the unique features of each SLA system to produce the required
muffler assembly prototypes. A large portion of the assembly was constructed on one SLA
system while an interior feature was constructed on another SLA system. While Rob was
cleaning the large SL part, the smaller piece was built in one hour. The parts were then joined using
SL material as the bonding agent. "It proves the versatility of both machines working together.
As model maker in the rapid prototyping lab, Rob is responsible for turn-around time, cost
and quality of parts produced on the SLA systems. Turnaround from CAD file to finished part is typically one week.
Company Profile
Xerox purchased their first SLA system in 1990, after winning the 1989 Malcolm Baldrige
National Quality Award.
Xerox Corporation is a global enterprise which develops, manufactures, markets, services
and finances a complete range of products and services designed to make offices more
productive. Xerox copiers, duplicators, digital production publishers, electronic printers,
facsimile prod-ucts, scanners, workstations, networks, computer software and supplies
are marketed in over 130 countries.
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