M. E.

(MECH) -Product design and Development

Subject: Rapid Prototyping

1. Compare and contrast solid,Liquid and powder based RP processes on following

variables
a. Material properties, color, dimensional accuracy and stability
b. Surface finish, machinability, environment resistance and support structures
c. Post build processing, concept model, form, fit and function model and patterns
2. By comparing the machine specifications, discuss the important specifications that
will determine their suitability for jewelry prototyping.
3. As opposed to many of the liquid-based RP systems which uses photosensitive
polymer, water is used in the Rapid Freeze Prototyping (RFP). What are the pros and
cons of using water?
4. Discuss the principle behind the two-laser-beam method. What are the major problems
in this method?
5. What causes missing facets or gaps to occur? Illustrate, with diagrams, the meaning
of degenerate facets? Explain overlapping facets?
6. What are the three types of non-manifold conditions?
7. What are the consequences of building a valid and invalid tessellated model?
8. What problems can the generic solution solve?
9. Describe the algorithm which is used to solve the missing facets’ problem.
10.What are some of the limitations of the solutions, both generic and special cases,
described to solve STL-related problems?
11.Name some other translators used in place of STL.
12.What problems does the SLC file format seek to address?
13.Describe newly proposed CLI, RPI and the LEAF formats briefly and contrast their
strengths and weaknesses.
14.How is application of RP models related to the purpose of prototyping? How does it
also relate to the materials used for prototyping?
15.Prove and illustrate how a generate facet can be repaired by the use of vector algebra.
16.How can the problem of overlapping facets be solved?
17.What causes missing facets or gaps to occur in STL models? Illustrate with diagrams,
the degenerate facets? Explain overlapping facets?
18.What are support structures? Discuss material type and its impact on final cost and
quality of prototypes?
19.How parts position within build envelope affects the final dimensional accuracy in
SLS and SLA parts?
20.Discuss post processing in rapid prototyping and its impact on quality and time
required?
21.Which are support materials used in different RP processes and how they are
removed?
22.Which step in the entire process chain is, in your opinion, the shortest? Most tedious?
Most automated? Support your choice
23.What are the applications of rapid prototyping in product development?
24.Which are the various tasks of post-processing? Name two RP processes that do not
require postcuring and one that does not require cleaning?
25.Discuss the principle behind the two-laser-beam method. What are the major problems
in this method?
26.Discuss the different file formats used for storing and processing of 3D models in
product development?
27.Describe newly proposed CLI, RPI and the LEAF formats briefly and contrast their
strengths and weaknesses?
28.Discuss STL file verification and repairing?
29.What are the typical RP applications in design? Briefly describe each of these
applications and illustrate them with examples.
30.List the types of industries that RP can be used in. List specific industrial applications.
31.What are the finishing processes that are used for RP models and explain why they are
necessary?
32.What are the typical RP applications in design? Briefly describe each of these
applications and illustrate them with examples.
33.What are the typical RP applications in engineering and analysis? Briefly describe
each of them and illustrate them with examples.
34.Describe how RP models can be used for pre-surgical operation planning. Use
appropriate examples to illustrate your answer.
35.Why and in what circumstances would RP be considered to assist implant fabrication?
36.Describe two examples of how rapid prototyping and tooling techniques would be
preferred over conventional methods in the improvement of patient care.
37.How would you differentiate between the following types of rapid tooling processes:
(a) direct soft tooling,
(b) indirect soft tooling,
(c) direct hard tooling, and
(d) indirect hard tooling.
38.Explain how a RP pattern can be used for vacuum casting with silicon molding. Use
appropriate examples to illustrate your answer.
39.What are the ways the RP pattern can be used to create the injection mold for plastic
parts. Briefly describe the processes.
40.Compare and contrast the use of RP patterns for
a. casting of die inserts,
b. sand casting, and
c. investment casting.
41.What are the RP systems that are suitable for sand casting? Briefly explain why and
how they are suitable for sand casting?
 42. Compare the relative merits of using LOM parts with SLA parts for investment
casting.
43. Explain whether RP technology is more suitable for “high technology” industries like
aerospace than it is for consumer products industries like electronic appliances. Give
examples to substantiate your answer.
44. Explain how RP systems can be applied to traditional industries like the jewelry, coin
and tableware industries.
45.In what form of material can Rapid Prototyping Systems be classified as solid-based?
Name three such systems.
46.Discuss how STL file format is most suitable in processing RP?
47.Discuss in detail the common errors in stl files? How they are rectified?
48.Explain LENS system based on cost, operating environment and operational overhead
and primary applications?
49.What are the typical RP applications in engineering and analysis? Briefly describe
each of them and illustrate them with examples
50.Classify the Different RP processes?
51.What is the impact of part orientation on quality and cost and time requirement in
prototype development?
52.Explain 3DP system based on cost, operating environment, operational overhead and
primary applications?
53.Describe how RP models can be used for pre-surgical operation planning. Use
appropriate examples to illustrate your answer.
54.Describe the process flow of Cubic’s Laminated Object Manufacturing?
55.Explain construction and working of SLA process?
56.Compare and contrast the laser-based LENS process and the FDM systems?
57.Why and in what circumstances would RP be considered to assist implant fabrication?
58.Explain construction and working of FDM process?
59.What are the advantages and disadvantages SLA systems?
60.Describe the process flow of 3D Systems’ MJM?
61.Describe two examples of how rapid prototyping and tooling techniques would be
preferred over conventional methods in the improvement of patient care.
62.Explain construction and working of LENS process?
63.Explain construction and working of LOM process?
64.Describe the process flow of Stratasys’ Fused Deposition Modeling?
65.How would you differentiate between the following types of rapid tooling processes:
(1) Direct soft tooling,
(2) Indirect soft tooling

short notes on any four of the following

a) Future of Rapid Prototyping

b) RP Applications in Archeology
a) liquid-based Rapid Prototyping Systems
a) Solid-based Rapid Prototyping Systems
c) Rapid manufacturing
d) Rapid tooling
e) Rapid tooling
f) RP Applications in Paleontology & forensic Science
g) Rapid manufacturing
h) Future of Rapid Prototyping
i) RP Applications in Science & Medicine
j) Compare the relative merits of using LOM parts with SLA parts for investment
casting
k) RP Applications in aerospace and electronic industries
l) Compare SLA and SGC processes
m) RP Applications in surgery
b) RP Applications in miniaturization(MEMS)
c) Powder-based Rapid Prototyping Systems
d) Briefly explain the slicing procedure used in SDM
e) RP applications in jewelry, coin and tableware industries
f) What are the RP systems that are suitable for sand casting? Briefly explain why
and how they are suitable for sand casting?
g) Compare the relative merits of using LOM parts with SLA parts for investment
casting.
h) Explain whether RP technology is more suitable for “high technology” industries
like aerospace than it is for consumer products industries like electronic
appliances. Give examples to substantiate your answer.
i) Explain how RP systems can be applied to traditional industries like the jewelry,
coin and tableware industries.
j) In what form of material can Rapid Prototyping Systems be classified as solid-
based? Name three such systems.