Rapid Prototyping Operations

Presentation by:
Raylan Vaz
1RV07ME082
VII B
 Introduction
 Subtractive processes
 Additive process
 Virtual Prototyping
 Applications
  Technology which considerably speeds the iterative product
development process

Fig: a) Examples of parts made by rapid prototyping b) Stereolithography model of cellular phone
 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
 Rapid prototyping is classified to 3-major
groups

Subtractive ( Removal of material )

Additive ( Adding of material )

Virtual ( Advanced computer base

visualization)
 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

 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
fused-deposition-modeling
operation
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
• 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 Fig : (a)Fused-deposition-modeling process.

lowered and subsequent layers are (b)The FDM 5000, a fused-decomposition-
formed modeling-machine.
 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 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 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 Fig :Stereolithiography Process
is reached
Fig: The selective laser sintering process
 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.
 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
 Layer of powder is first deposited on part
build cylinders

 A laser beam controlled by instruction from

3-D 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
 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

 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

Similar to ballistic particle manufacturing

Fig:Three dimensional 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 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

cross-sectional 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.
Fig : (a) Laminated object-manufacturing process (b)Crankshaft-part example made by LOM
 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

lead-time of complex products/processes

 Allows the exotic, unconventional designs

be prototyped, rapidly and cost-effectively
 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.
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.

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