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Rapid Prototyping

Presented by

Vivekanand.K

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CONTENTSHistory of Rapid prototyping

Introduction

Basic process

Rapid prototyping techniques

Traditional development process versus Rapid prototyping process

Performing Rapid prototyping

Rapid prototyping pros and cons

Future developments and conclusion

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History of RP

In 1967, Herbert Voelcker, a prof by profession questioned himself about the possibilities of doing interesting things with the computer controlled and automatic machine tools,hence RP was born.

In 1970’s, Voelcker developed the basic tools of mathematics that clearly describe the three dimensional aspects and resulted in the earliest theories of algorithmic and mathematical theories for solid modeling.

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Introduction

The term rapid prototyping (RP) refers to a class of technologies that can automatically construct physical models from Computer-Aided Design (CAD) data.

These "three dimensional printers" allow designers to quickly create tangible prototypes of their designs, rather than just two-dimensional pictures. Such models have numerous uses.

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The Basic process

1.Create a CAD model of the design

2.Convert the CAD model to STL format

3.Slice the STL file into thin cross-sectional layers

4.Construct the model one layer atop another

5.Clean and finish the model

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CAD Solid ModelCAD Solid Model

• Solid model or closed surface model required

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.STL File.STL File

• Software generates a object description• File consists of the X, Y, Z coordinates of the

three vertices of each surface triangle, with an index to describe the orientation of the surface normal

• Support generation to hold overhung surfaces during build

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.STL File.STL File

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Slicing the FileSlicing the File• Series of closely spaced horizontal planes

are mathematically passed through the .stl file

• Generate a ‘.sli’ file : a series of closely spaced 2D cross-sections of the 3D object

• Typical Z thickness 0.006” (0.150 mm)• The pre-processing software slices the STL

model into a number of layers from 0.01 mm to 0.7 mm thick, depending on the build technique.

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• Part sliced• Supports sliced• RP technology parameters set

• layer thickness, scan speed,...

• Send file to RP machine• RP machine build one layer at a time from

polymers,paper,or powdered metal.

Final Build FileFinal Build FilePart

Supports

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Post-processingPost-processing

• Removal of part from platform

• Removal of supports from part

• Cleaning of part (wiping, rinsing, ... )

• Finishing part (curing, sanding, polishing, … )

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RP Techniques► Stereolithography 

► Laminated Object Manufacturing

► Selective Laser Sintering

► Fused Deposition Modeling

► Solid Ground Curing

► 3-D Ink-Jet Printing

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A)Stereolithography 

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B)Laminated Object Manufacturing

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C) Selective Laser Sintering

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D)Fused Deposition Modeling

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FDM material

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E)Solid Ground Curing

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F) 3-D Ink-Jet Printing

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Performing RPSelect a ToolForm a TeamRapid Prototyping Process

Analyze proposed system Identify initial customer requirements Identify objects and actions Put together related objects and actions Prototype panels Get feedback Improve prototype Iterate Convert prototype code to actual code Get feedback Improve actual code IterateRelease the product

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Comparison

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Rapid Prototyping Pros and Cons

•PROS:

Saves time and money

Promotes consistency in user interface design

Allows early customer involvement

Changes perceived ownership to customers

Shows progress to management in a concrete way

Allows marketers and planners to ensure that customer needs are met

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•CONS:

. Metal prototypes are difficult to make, though this should change in the near future

Sometimes encourages prototyping by programmers rather than domain experts

Usually does not produce reusable code

Slows development process if put under formal configuration control

Cost of machine is very high

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Applications

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• In Engineering

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Applications

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•Medical applications

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Applications

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•Architectural applications

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FUTURE DEVELOPMENTS

. "Rapid" prototyping machines are still slow by some standards. By using faster computers, more complex control systems, and improved materials, RP manufacturers are dramatically reducing build time.

Another future development is improved accuracy and surface finish.

Another important development is increased size capacity.

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CONCLUSION

Growth into new markets and industries will redefine the role of RP and this will redefine our future.

Of course, rapid prototyping is not perfect. Part volume is generally limited to 0.125 cubic meters or less, depending on the RP machine

The limitations aside, rapid prototyping is a remarkable technology that is revolutionizing the manufacturing process.

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