Lesson Outcomes:

After todays lecture, students are

expected to:
Analyze the process of rapid
prototyping operation

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Rapid-Prototyping Operations

Introduction
Rapid prototyping is the automatic construction of

physical objects using solid freeform fabrication.

Solid freeform fabrication (SFF) is a technique for
manufacturing solid objects by the sequential delivery
of energy and/or material to specified points in space
to produce that solid.
SFF is sometimes referred to as rapid prototyping,
rapid manufacturing, layered manufacturing and
additive fabrication.
Used mostly in the development stage of a new
product or low production quantity
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Introduction (cont.)
RP takes virtual designs from CAD or animation

modeling software, transforms them into thin

horizontal cross sections, still virtual, and then
creates each cross section in physical space, one
after the next until the model is finished.
The machine reads in data from a CAD drawing and
lays down successive layers of liquid, powder, or
sheet material, and in this way builds up the model
from a series of cross sections.
These layers, which correspond to the virtual cross
section from the CAD model, are joined together or
fused automatically to create the final shape.

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Parts Made by RapidPrototyping

(c)
(a)

(b)

Examples of parts made by rapid-prototyping processes: (a) selection

of parts from fused-deposition modeling; (b) stereolithography model of
cellular phone; and (c) selection of parts form three-dimensional printing.
Source: Courtesy of Stratasys, Inc., (b) and (c) Courtesy of 3D Systems,
Inc.
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Introduction (cont.)
Classification of Rapid Prototyping

1. Subtractive ( Removal of material )

2. Additive ( Adding of material )
3. Virtual ( Advanced computer base visualization)

Almost materials can be manufactured

through a rapid-prototyping operation, but
polymers are the work piece material most
commonly used today.

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Subtractive Process
Subtractive process use computer based
prototype technology to speed the process
Essential technologies for subtractive
prototyping :

i.
ii.

iii.
iv.

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
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Subtractive Process (cont.)

For shape verification, polymer or wax

is used
For actual application, a machining
process still required
Production time varies from few days to
weeks

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Additive Process
Build parts in layer by layer (slice by slice as

stacking a loaf of bread) & require elaborate

software
Steps;

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

Production time varies from few minutes to

hours

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Characteristics of Additive RapidPrototyping Technologies

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Stereolithography
Works based on the principle of curing liquid

photomer into specific shape

A vat which can be lowered and raised filled
with photocurable liquid polymer
Laser generating U-V beam is 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 and c is
reached as shown in the figure below
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Stereolithography

Schematic illustration of the stereolithography process.

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Computational
Steps in Rapid
Prototyping
The computational steps in
producing a stereolithography
file. (a) Three-dimensional
description of each part. (b)
The part is divided 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. Also shown is the
extruder path at section A-A
from (c) for a fuseddeposition-modeling
operation.
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Fused Deposition Modeling

FDM extrudes hot plastic or wax through a

nozzle, building up a model.

A gantry robot controlled extruder head
moves in two principle directions over a table
Table can be raised or lowered as needed
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
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Fused-Deposition-Modeling

(a) Schematic illustration of the fused-deposition-modeling process. (b) The

FDM 5000, a fused-deposition-modeling machine. Source: Courtesy of Stratysis,
Page 16
Inc.
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Selective Laser Sintering (SLS)

Selective laser sintering uses a laser to fuse

powdered nylon, elastomer, or metal. Additional

processing is necessary to produce fully dense
metal part.
Basic elements in this process are bottom of
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.
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Selective-Laser-Sintering

Schematic illustration of the selective-laser-sintering process. Source:

After C. Deckard and P. F. McClure.
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Selective Laser Sintering (SLS)

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
and this cycle is repeated again and dust is
shaken off
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Laminated object manufacturing

(LOM )
Uses layer of papers 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 cross-sectional
pattern
LOM uses sheets as thin as 0.05mm
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Laminated-Object-Manufacturing

(a) Schematic illustration of the laminated-object-manufacturing

process. (b) Crankshaft-part examples made by LOM. Source: (a)
Courtesy of Helsis, Inc. (b) After L. Wood.
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Virtual Prototyping
Modeling and simulation of all aspects of a

prototype by a realistic visualization.

All aspects of design processes such as
mechanical design, kinematics, dynamics, and
controls.
Simple type use complex software & 3D
graphics routines to change the view on a
computer screen.
Complicated versions use virtual-reality
headgear and gloves with appropriate
sensors.
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Virtual Prototyping (cont.)

Advantages;
Instantaneous rendering of parts, where
the best design in the shortest lead-time of
complex products/processes
Allows the exotic, unconventional designs
be prototyped, rapidly and cost-effectively
More advanced systems used very

costly.

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Applications of Rapid Prototyping

Production of individual part
RP can be used to manufacture

marketable products directly especially

involve the polymer parts.
Pattern used in investment casting also
produced with RP techniques shown
below

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Investment Casting Using RapidPrototyped Wax Parts

Manufacturing steps for investment casting that uses rapid-prototyped wax parts as blanks.
This method uses a flask for the investment, but a shell method also can be used. Source:
Courtesy of 3D Systems, Inc.
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Rapid Tooling
Rapid Tooling (RT) is a process which either

uses a RP model as a pattern to create a mould

quickly or uses the RP process directly to
fabricate a tool for a limited volume of
prototypes.
Advantages;
a)Tooling time is much shorter than for a conventional
tool.
b)Tooling cost is much less than for a conventional
tool.
c)Tool life(disadantage) is considerably less than
for a conventional tool.
d)Tolerances are wider than for a conventional tool.
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Rapid Tooling for a RearWiper Motor Cover

Rapid tooling for a rear-wiper motor cover. Source: Courtesy

of 3D Systems, Inc.
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Advantages of Rapid Prototyping

Reduce product development time and cost
Get products to market sooner
Enhance communications between marketing,

engineering, manufacturing, and purchasing

Present physical model at critical design
reviews
Perform functional prototype testing before
committing to tooling
Generate precise production tooling
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Disadvantages of Rapid
Prototyping
Investment cost very high
Maintenance cost too high
Limitation on materials availability

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Thats all for today..

Any questions??

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IQ + EQ + SQ = TQ
Thank You for coming and
see you again..

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