Rapid Prototyping Manufacturing

MECH 311
J OY S H A N T H A N G A RA JA H
MEHDI AIT BEN LA ARBI

What is a prototype?
A

prototype is an early sample of a product

Used as a proof of concept
Allows manufacturers to examine a design more closely
Can be used to test new designs

Development of manufacturing
over the last two centuries

What is Rapid Prototyping?

The aim is to use additive manufacturing of material instead of
subtractive ones or formative ones.
Examples of subtractive manufacturing include: Turning, Boring,
Milling, Drilling
Subtractive technologies may be used but only as a secondary,
finishing process to improve precision and accuracy.
Can be also referred to as free-form fabrication, computer automated
manufacturing or layered manufacturing

What is Rapid Prototyping?

Applications of RPM

Liquid-based Systems
Material that is to be process exists in liquid form, ex. Polymers and wax.
Contains 4 main technologies:

Stereolithography
Solid-Based Curing
Fused Deposition Modeling (FDM)
Ballistic particle manufacturing (BPM)

Stereolithography
Process is based on photosensitive liquid resin which solidifies in the presence
of UV light.
After one layer is formed by laser, the build platform on which the layer rests
will move one thickness layer down and then a new layer is formed on top of
the previously existing layer.
This process is repeated until the part is obtained

Solid-Based Curing
Very similar to Stereolithography with the addition of milling
operations after each layer is formed.

Fused Deposition Modeling

(FDM)
Material exists in solid form that is spooled
Material is heated to temperatures slightly above its melting
temperatures and then deposited by a moving nozzle to form the layer.
Support materials are also used for complex part shapes which are
later removed.

Ballistic Particle Manufacturing

(BPM)
Micro-droplets of molten wax are fired onto the platform. Droplets will solidify
when they make contact with the previous layer.
Nozzle moves while platform is stationary

Powder-Based Systems
This method uses powder material as an input. Contains 2 main technologies:
3D Printing
Selective Laser Sintering (SLS)

3D Printing

Selective Laser Sintering (SLS)

Laser beam is used to cure a slice of powder that is in direct contact with the
beam.
Once a layer is formed, the elevator moves one thickness level down and a new
layer of power is rolled on to be sintered again.

Solid-Based Systems
Laminated Object Manufacturing (LOM)
Slices are cut in required contour from sheet material before using a laser beam.
A hot roller binds the slice to the previous one, which activates an adhesive.

Advantages and Disadvantages

of using RPM in Manufacturing
ADVANTAGES

DISADVANTAGES

Can easily make very complex parts

Cost efficient for both low and high volume production
Can produce multiple parts that are functional without the requirement for
assembly
Minimizes material waste
Design errors can be quickly fixed with the modification of computer CAD
models

Very poor precision and surface roughness for final products

High precision RPM systems are very expensive.
Mechanical properties such as elasticity and hardness are also lower.
For this reason RPM parts cannot be used as final products but only
prototypes.