Rapid prototyping

Introduction
Subtractive processes
Additive process
Virtual Prototyping
Applications

Rapid prototyping
Technology which considerably speeds the iterative product development process

Fig: a) Examples of parts made by rapid prototyping b) Stereolithography model of cellular phone

Advantages
CAD data files can be manufactured in hours.
Tool for visualization and concept verification.
Prototype used in subsequent manufacturing
operations to obtain final part
Tooling for manufacturing operations can be
produced

Classification of Rapid Prototyping

Rapid prototyping is classified to 3-major groups
Subtractive ( Removal of material )
Additive ( Adding of material )
Virtual ( Advanced computer base
visualization)

Subtractive Process

Subtractive process use computer based Prototype technology to

speed the process

Essential Technologies for subtractive prototyping :

Computer based drafting packages ( 3-D representation of parts)

Interpretation software (Translation of cad file to manufacturing

software)

Manufacturing Software (Planning Machining operations)

Computer-Numerical Control Machinery

Additive Process

Build parts in layer by layer (slice by slice as stacking a loaf of bread)

Fig: The computational steps in

producing a stereolithography
file a) Three dimensional
description of part b)The part is
divides into slices (only one in
10 is shown) c)support material
is planned d)A set of tool
directions is determined to
manufacture each slice. Shown
is the extruder path at section
A-A from c) For a fuseddeposition-modeling operation

Additive Process
Require elaborate software
1 : Obtain cad file
2 : Computer then constructs slices of a 3-dimensional
part
3 : slice analyzed and compiled to provide the rapid
prototyping machine
4 : setup of the proper unattended and provide rough part
after few hours
5 : Finishing operations and sanding and painting
6:labor intensive and production time varies from few
minutes to few hours

Fused Deposition Modeling

A gantry robot controlled extruder

head moves in two principle
directions over a table

Table can be raised or lowered as

needed

Thermo plastic or wax filament is

extruded through the small orifice
of heated die

Initial layer placed on a foam

foundation with a constant rate

Extruder head follows a

predetermined path from the file

After first layer the table is lowered

and subsequent layers are formed

Fig : (a)Fused-deposition-modeling process.

(b)The FDM 5000, a fused-decompositionmodeling-machine.

Fused Deposition Modeling

Fig: a)A part with protruding section which requires support material b) Common support structures used in
rapid-prototyping machines

Stereolithiography

Works based on the principle of

curing liquid photomer into specific
shape

A vat which can be lowered and

raised filled with photocurable liquid
acrylate polymer

Laser generating U-V

focused in x-y directions

The beam cures the portion of photo

polymer and produces a solid body

This process is repeated till the level b

is reached as shown in the figure

Now the plat form is lowered by

distance ab

Then another portion of the cylinder is

shaped till the portion is reached

beam

is

Fig :Stereolithiography Process

Selective laser sintering (SLS) :

Fig: The selective laser sintering process

Selective laser sintering

SLS based on sintering of nonmetallic powders onto a
selective individual objects
Basic elements in this process are bottom of processing
chambers equipped with 2 cylinders
Powder feed cylinder which is raised incrementally to
supply powder to part-build cylinder through a roller
mechanism
Part-build cylinder which is lowered incrementally to where
the sintered part is formed.

Selective laser sintering

Set of the proper computer files and the initiation of
the production processes
Machine operate unattended and provide rough part
after few hours
Finishing operations as sanding and painting
Labor intensive & production time varies from few
minutes to few hours

Selective laser sintering

Layer of powder is first deposited on part build
cylinders
A laser beam controlled by instruction from 3D file is focused on that layer tracing &
sintering a particular cross-section into a solid
mass & dust is taken off.
Another layer of powder is now deposited this
cycle is repeated again and dust is shaken off

Solid Base curing :

Also called Solid ground

curing

Entire slices of part are

manufactured at one time

So large throughput is
achieved

Most expensive & time

consuming

The entire process is shown

Fig:The solid based curing process

Ballistic Particle Manufacturing

Ballistic particle manufacturing
Stream of material , such as plastic ,ceramic, metal or wax
ejected through small orifice at a surface
Mechanism similar to inkjet mechanism ( piezo-electric
pump)
Operation repeats similar to other process to form a part
with layers of wax deposited on top of each other
Ink jet heat guided by three-axis robot

3-D Printing process

Similar to ballistic particle manufacturing

Fig:Three dimensional printing process

3-D Printing process

Print head deposits an inorganic binder material
Binder directed onto a layer of ceramic metal powder
A piston supporting the powder bed is lower incrementally with
each step a layer is deposited and unified by binder
Commonly used materials Aluminum oxide, silicon carbide,silica
and zirconium.
Common part produced by 3-D printing is a ceramic casting shall
Curing around 150 C 300 F
Firing 1000 C 1500 C

Laminated object manufacturing (LOM )

Laminated implies laying down of layers which are adhesively
bonded to one another
Uses layer of paper or plastic sheets with heat activated glue on
one side of the product parts
Excess material to be removed manually
Simplified by preparing the laser to burn perforations in crosssectional pattern
LOM uses sheets as thin as 0.05mm
Compressed paper has appearance and strength of soft wood ,
and often mistaken for elaborate wood carvings.

Laminated Object Material (LOM)

Fig : (a) Laminated object-manufacturing process

(b)Crankshaft-part example made by LOM

Virtual prototyping
Virtual prototyping (modeling and simulation of
all aspects of a prototype, i.e. mechanical
design, kinematics, dynamics, and controls
accompanied by a realistic visualization).
Realizing the best design in the shortest leadtime of complex products/processes
Allows the exotic, unconventional designs be
prototyped, rapidly and cost-effectively

Applications of Rapid Prototyping

Production of individual parts
Production of tooling by Rapid Prototyping (Rapid Tooling)

Fig: Manufacturing steps for investment casting that uses rapid prototyped wax parts as blanks.

Rapid Tooling
The term Rapid Tooling (RT) is typically used to describe a process which
either uses a Rapid Prototyping (RP) model as a pattern to create a mold
quickly or uses the Rapid Prototyping process directly to fabricate a tool
for a limited volume of prototypes .
a)Tooling time is much shorter than for a conventional tool. Typically, time to
first articles is below one-fifth that of conventional tooling.
b) Tooling cost is much less than for a conventional tool. Cost can be below
five percent of conventional tooling cost.
c) Tool life is considerably less than for a conventional tool.
d) Tolerances are wider than for a conventional tool.

Rapid Tooling

Fig: Manufacturing steps in sand casting that causes that uses rapid-prototyped patterns

Rapid Tooling

Fig: Manufacturing steps in sand casting that causes that uses rapid-prototyped patterns