RAPID PROTOTYPING 2
COURSE
:Advanced CAD
Submitted to : [Link] KUMAR
Assistant professor Department of Mechanical Engineering National Institute of Technology Warangal
Prepared by [Link]-123559 [Link]-123563 [Link] kumar-123564 [Link] -123565
Rapid Prototyping (RP)
A family of unique fabrication processes developed to make
engineering prototypes in minimum lead time based on a
CAD model of the item.
The traditional method is machining (time consuming) RP allows a part to be made in hours or days rather than
weeks, given that a computer model of the part has been
generated on a CAD system
Why Rapid Prototyping
Because product designers would like to have a physical model of a new part or product design rather than just a computer model or line drawing Creating a prototype is an integral step in design A virtual prototype may not be sufficient for the designer to visualize the part adequately Using RP to make the prototype, the designer can visually examine and physically feel the part and assess its merits and shortcomings.
Classification of RP Technologies
There are various ways to classify the RP techniques
that have currently been developed
The RP classification used here is based on the form
of the starting material:
1. 2. 3.
Liquid-based Solid-based Powder-based
Liquid-Based Rapid Prototyping Systems
Starting material is a liquid
The system Includes the following processes:
Stereolithography Solid ground curing
Droplet deposition manufacturing
Solid-Based Rapid Prototyping Systems
Starting material is a solid
Solid-based RP systems include the following
processes:
Laminated object manufacturing Fused deposition modeling
Laminated Object Manufacturing (LOM)
Solid physical model made by stacking layers of sheet stock, each an
outline of the cross-sectional shape of a CAD model that is sliced into
layers .
Starting sheet stock includes paper, plastic, cellulose, metals, or fiber-
reinforced materials .
The sheet is usually supplied with adhesive backing as rolls that are
spooled between two reels .
After cutting, excess material in the layer remains in place to support
the part during building .
Laminated Object Manufacturing
Figure 1 Laminated object manufacturing.
Laminated Object Manufacturing (LOM)
Applications
Applicable for a wide range of product, equipment for aerospace
or automotive, consumer products, and medical devices .
Prototypes for design, analysis and functional testing. Tools for production. Small volume of finished goods .
Fused Deposition Modeling (FDM)
RP process in which a long filament of wax or polymer is extruded onto
existing part surface from a workhead to complete each new layer .
Workhead is controlled in the x-y plane during each layer and then
moves up by a distance equal to one layer in the z-direction.
Extrudate is solidified and cold welded to the cooler part surface in
about 0.1 s .
Part is fabricated from the base up, using a layer-by-layer procedure.
Fused Deposition Modeling
Fused Deposition Machine
FDM material
Fused Deposition Modeling (FDM)
o Applications Models for conceptualisation and presentation Prototypes for design, analysis and functional testing Patterns and masters for tooling. Models can be used as patterns
for investment casting, sand casting and moulding
Powder-Based RP Systems
Starting material is a powder
Powder-based RP systems include the following:
Selective laser sintering
Three dimensional printing
Selective Laser Sintering (SLS)
Moving laser beam sinters heat-fusible powders in areas corresponding to the CAD geometry model one layer at a time to build the solid part.
After each layer is completed, a new layer of loose powders is spread
across the surface.
Layer by layer, the powders are gradually bonded by the laser beam
into a solid mass that forms the 3-D part geometry.
In areas not sintered, the powders are loose and can be poured out of
completed part.
Selective Laser Sintering
Selective Laser Sintering (SLS)
Applications Concept models Functional models and working prototypes Wax casting pattern Polycarbonate patterns. These build faster than wax patterns and
are ideally suited for design with thin walls and fine features. These pattern are also durable and heat resistant
Metal Tools. Direct rapid prototype of tools of moulds for small or
short production runs.
Three Dimensional Printing (3DP)
Part is built layer-by-layer using an ink-jet printer to eject adhesive bonding material onto successive layers of powders.
Binder is deposited in areas corresponding to the cross sections of
part, as determined by slicing the CAD geometric model into layers.
The binder holds the powders together to form the solid part, while
the unbonded powders remain loose to be removed later.
To further strengthen the part, a sintering step can be applied to bond
the individual powders.
3D Printing
Inkjets
Three Dimensional Printing (3DP)
Applications
o CAD-Casting metal parts. A ceramic shell with integral cores
can be fabricated directly from the CAD model
o Direct metal parts. It is adaptable to a variety of material
systems, allowing the production of metallic/ceramic parts with novel composition
o Prototypes with colours and elastic feature
Rapid Prototyping (RP)
Features of RP Systems Layer thickness(mm) - 0.05 - 0.3(SLA); 0.1 - 1(LOM.);
~0.05(FDM); ~0.08(SLS); 0.01 - 0.15(SGC)
Accuracy(mm) - 0.01- 0.2(SLA); 0.1 - 0.2(LOM); 0.127 -
0.254(FDM); 0.03 - 0.38(SLS); 0.05 - 0.5(SGC)
Manufacturer - 3D System, Stratasys, Helisys, DTM, EOS, etc.
RP Applications
Applications of rapid prototyping can be classified
into three categories:
1. 2. 3.
Design Engineering analysis and planning Tooling and manufacturing
Design Applications
Designers are able to confirm their design by building a real
physical model in minimum time using RP
Design benefits of RP:
Reduced lead times to produce prototypes Improved ability to visualize part geometry Early detection of design errors Increased capability to compute mass properties
Engineering Analysis and Planning
Existence of part allows certain engineering analysis and planning
activities to be accomplished that would be more difficult without the physical entity
Comparison of different shapes and styles to determine aesthetic
appeal
Wind tunnel testing of streamline shapes
Stress analysis of physical model Fabrication of pre-production parts for process planning and tool
design
Tooling Applications
Called rapid tool making (RTM) when RP is used to
fabricate production tooling
Two approaches for tool-making:
1. Indirect RTM method 2. Direct RTM method
Indirect RTM Method
Pattern is created by RP and the pattern is used to
fabricate the tool
Examples:
Patterns for sand casting and investment casting Electrodes for EDM
Direct RTM Method
RP is used to make the tool itself
Example:
3DP to create a die of metal powders followed by
sintering and infiltration to complete the die
Manufacturing Applications
Small
batches of plastic parts that could not be
economically molded by injection molding because of the
high mold cost.
Parts with intricate internal geometries that could not be
made using conventional technologies without assembly.
One of a kind parts such as bone replacements that must be
made to correct size for each user .
Problems with Rapid Prototyping
Part accuracy:
Staircase appearance for a sloping part surface due to layering .
Shrinkage and distortion of RP parts.
Limited variety of materials in RP
Mechanical performance of the fabricated parts is limited by the
materials that must be used in the RP process
THANK YOU
