1. Advantages of 3D PrintingThe most successful companies have adopted 3D printing as a critical partof the iterative design process to:Reduce Development CostsCut traditional prototyping and tooling costsIdentify design errors earlierReduce travel to production facilitiesSpeed Time To MarketCompress design cycles by 3D printing multiple prototypes on demand, right in your officeIncrease InnovationPrint prototypes in hours, obtain feedback, refine designs and repeat the cycle until designs areperfectImprove CommunicationHold a full color, realistic 3D model in your hands to impart infinitely more information than acomputer imageCreate physical 3D models quickly, easily and affordably for a wide variety of applicationsWin BusinessBring realistic 3D models
2. Complete 3D models can be manufactured including those with hollow parts thatcould not possibly be made by hand in one piece, even by the most skilled engineeror craftsperson. Parts such as bearings, engineering parts and complex workingmodels can be manufactured.A variety of epoxy and waxes can be applied to the completed model. These increasethe strength of the model, its temperature resistance and allows paint and finishes tobe applied realistically.The use of specialized resin will give models the properties of rubber.Prototyping machines can even be used to produce highly accurate patterns forcasting.Manufactured model parts can be combined with real parts to produce a fullyfunctioning product that can then be tested and evaluated
3. RAPID PROTOTYPINGLeading product designers use prototyping machines to accelerate the designprocess and bring products to market sooner. Applications include:Concept Models - Get early design feedback, improve communication, and testergonomicsFunctional Testing - Verify designs for form, fit and function prior to full-scaleproduction; plus reduce costly modifications to production toolingFinite Element Analysis - Produce prototypes displaying color finite element analysisdata right on the part. Improve collaboration among project teams, and identifydesign flaws earlierPresentation Models - Communicate clearly with peers and clients, and performfocus group testingPackaging Development - Streamline the design process for glass and plasticpackaging used in consumer
4. Why create casting patterns utilizing 3D CAD dataAs is typical in the creation of prototype castings, traditional pattern manufacturing costs caneasily be more expensive than the actual costs of pouring all the parts associated to a shortprototype casting run. In addition, the lead time for the creation of these patterns can oftenbe measured in weeks.In the following example, a new drive pinion flange design is taken from concept 3D CADmodel to final prototype pattern pieces in the matter of 3 days. Resulting in the patterns beingused to create 250 rapid prototype cast iron castings at a fraction of the cost and timeassociated with traditional patterns.
5. 1. Starting with the 3D CAD data.Accurate 3D CAD data is where it all starts. If the base CAD model contains errors, thoseerrors will carry through to the final cast iron parts, ensuring that the CAD model is at theappropriate release level and has been thoroughly designed and checked is of utmostimportance.Figure A shows the final machining CAD model of the new concept flange design.In this machined CAD model, blue represents the machined surfaces and tan represents theremaining cast surfaces. The casting CAD model, shown in Figure B, reflects the partgeometry of the actual final prototype cast iron flange that will be received from thefoundry.
6. Figure A shows the final machining CAD model of the new concept flange design. In this machined CAD model, blue represents the machined surfaces and tan represents the remaining cast surfaces. The casting CAD model, shown in Figure B, reflects the part geometry of the actual final prototype cast iron flange that will be received from the foundry. Figure A
7. Figure B
8. Finite Element AnalysisProduce prototypesdisplaying color finiteelement analysis data righton the part. Improvecollaboration amongproject teams, and identifydesign flaws earlier
9. Model: Electric MotorType: ZP 150 HIGH PERFORMANCE POWDER
10. Model: Flange and SprocketType: Vero Resin Black
11. Model: Single axle driveType: ZP 150 HIGH PERFORMANCE POWDER
12. Model: MouldType: VERO RESIN CLEAR
13. Model: Pipe Hangar BracketType: VERO RESIN GRAY
14. Choosing a ProcessDetermine the process that is the best fit for your project by using the tools shown.Step 1:Begin by using the decision tree on the next slide to narrow down which factors are ofhighest importance to you based on the stage you are at in the prototyping process,referring to the definitions on page 8 as needed.Step 2:Based on the recommended attributes for your most important factor(s) from Step 1,compare the processes using the process decision making chart on the next page todetermine which process will be the best fit for your project.
15. What stage are you at in What factor(s) is/are most Recommended attributes tothe prototyping process? important to you? consider when choosing a process.
16. Rapid PrototypeDesign Process Flow
17. Conclusion:The future for 3D printing seems very promising, it is the fastest growing part of the rapid-prototyping industry with revenues this year expected to be approximately a billion USdollars. Many industries are showing huge amounts of interest and are seeing great potentialin different applications where they could utilize three dimensional printing. The US armyhave experimented using rapid prototyping to create parts for broken tanks, guns and otherhardware in combat situations. Businesses believe a rapid prototyping machine could proveinvaluable in showing factories how to assemble parts remotely, for example in China. EvenNASA has requested a high resolution machine to manufacture crucial parts in space.In conclusion what is stopping you being part of a truly revolutionary technology, whichcould become one of the major breakthroughs of the twenty first century? 3D printing hasmerely been science fiction until recently, where it is now most certainly science fact. Whatcan we expect to see in the not so far away future? Well one ultimate goal is printableorganic parts, for example replacement organs, identical skin grafts and even limbs, tocombat victims of illness, disease and war.
18. Three-dimensional printing from digitaldesigns will transform manufacturing andallow more people to start making things COMMUNICATE IN ALL DIMENSIONS