4th Seminar RapidPrototyping Senior Seminar Ahmedawad

Rapid Prototyping

Contents

• Manufacturing Process Classification

• Technologies

• Process Cycle

• Advantages

• Applications

• Comparison

• Applications

• Conclusion

Manufacturing Process Classification

Consolidation

Subtractive

Additive

Rapid Prototyping

The term "rapid prototyping" is a relatively

new expression for the generation of three-

dimensional models manufactured without

the need for machining or tooling.

Applications

• Rapid prototyping

• Rapid tooling

• Rapid manufacturing

Rapid prototyping

http://ccmodels.com/index.html

Prototypes for visualization, form/fit testing, and

functional testing

Classic construction models

Rapid tooling

Molds and dies fabricated using additive

processes

Rapid manufacturing

Low-to-medium volume production runs of

end-use parts

Process Cycle

3D solid modeling

Slicing the part

Fabrication of the part

Post processing

• Create CAD model - For all additive

processes, the designer must first use

Computer-Aided Design (CAD) software to

create a 3-D model of the part.

• Convert CAD model into STL model -

Each form of CAD software saves the

geometric data representing the 3-D

model in different ways.

• Slice STL model into layers - Using

specialized software into thin cross

sectional layers

• Build part one layer at a time - The

machine builds the part from the STL

model by sequentially forming layers of

material on top of previously formed

layers.

• Post-processing of part - After being built,

the part and any supports are removed

from the machine

Advantages

• Speed.

• Part complexity

• Low-volume

Technologies

Liquid-based processes 1

• Material used: Photopolymer

• Example: Stereolithography (STL)

Powder-based processes 2

•Material Used: powders of polymers, metals, or ceramics

Example :Three Dimensional Printing (3DP(

Solid-based processes 3

• Material used: paper

• Example: Laminated Object Manufacturing (LOM)

Stereolithography (SLA)

• Material type: Liquid (Photopolymer)

Stereolithography (SLA)

• Time to complete a single layer :

𝑇𝑖 =𝐴𝑖

𝑣 + 𝐷+ 𝑇𝑟

Laminated Object Manufacturing (LOM)

• Material type: Solid (Sheets)

Laminated Object Manufacturing (LOM)

Three Dimensional Printing (3DP)

• Material type: Powder

Three Dimensional Printing (3DP)

Comparison

• Material

• part size

• Surface finish

• Accuracy

• Time

SLA 3DP LOM

Material typeLiquid

(Photopolymer)Powder Solid (Sheets)

MaterialsThermoplastics

(Elastomers)

Ferrous metals

such as

Stainless steel;

Non-ferrous

metals such as

Bronze;

Elastomers;

Composites;

Ceramics

Thermoplastics

such as PVC;

Paper;

Composites

Tensile Strength

55

35

19

SLA LOM 3DP

Str

es

s (

MP

a)

technology

Tensile Strength

Hardness (Shore D)

8678

62

SLA LOM 3DP

Hard

ne

ss

(S

ho

re D

)

technology

Hardness (Shore D(

Max part size

0.2307

0.7872

0.5619

SLA LOM 3DP

Vo

lum

e (

m^

3)

technology

Max part size

0.127

0.25

0.33

SLA LOM 3DP

Th

ick

ne

ss

(m

m)

technology

Layer Thickness

SLA LOM 3DP

Surface finish Smooth Rough Rough

Accuracy Best Average Fair

Time average fast Very fast

Water, chemical

resistance Poor Best Poor

SLA LOM 3DP

Form/fit testing,

Functional testing,

Rapid tooling

patterns,

Very detailed parts,

Presentation models,

Form/fit testing,

Less detailed parts,

Rapid tooling patterns

Concept models,

Limited functional

testing

industrial models,

Consumer goods

Applications

In 2011 University of Southampton engineers at

the University of Southampton in the UK have

designed, printed, and sent skyward the world’s

first aircraft manufactured almost entirely via 3-D

printing technology

Conclusion

• Now the time has come where, the design

engineer just can imagine the new design

and within the few minute the product will

be ready with this technology (prototyping)

• Research & Development Engineers

developing new shapes, size, design, type

of various component for the establishing

machine or product