Rapid Prototyping Dan Larochelle  Chief Technology Officer  intelitek
<ul><li>Prototyping challenges the student to apply the fundamental concepts they learned in their STEM program </li></ul>...
<ul><li>Prototypes are an essential  tool in product design </li></ul><ul><li>Prototypes are a way for students to express...
Is this Rapid Prototyping?
<ul><li>Rapid Prototyping: </li></ul><ul><ul><li>Create something quickly </li></ul></ul><ul><li>ASTM International (2009)...
<ul><li>Subtractive processes remove material from a solid workpiece and the result is the final part </li></ul><ul><li>Ex...
CAD/CAM/CNC Process
<ul><li>Parts are made layer by layer  </li></ul><ul><li>Each layer is a cross section of the part </li></ul><ul><li>deriv...
<ul><li>Typical steps of the AM process: </li></ul><ul><ul><li>CAD </li></ul></ul><ul><ul><li>Convert to STL </li></ul></u...
<ul><li>A sheet of material is glued to the build platform </li></ul><ul><li>A pattern from the model is cut into the shee...
<ul><li>Material is fed to an extruding tip where is it melted into a fine stream to create the model layer by layer </li>...
<ul><li>A very thin layer of powdered material is applied to the building platform </li></ul><ul><li>The printing head dep...
<ul><li>A photo-sensitive resin is propelled through an extruding tip to build the part </li></ul><ul><li>As the jetting h...
<ul><li>Thin coatings of photo-sensitive resin are solidified with a low powered UV light, electron beam or laser </li></u...
<ul><li>A photo-sensitive resin is sprayed onto the build platform layer by layer, similar to SLA </li></ul><ul><li>The ma...
<ul><li>A fine powder is propelled by an inert gas through a nozzle and melted by a high powered laser </li></ul><ul><li>P...
<ul><li>A very thin layer of material is applied to the building platform </li></ul><ul><li>A carbon dioxide laser melts t...
<ul><ul><li>Improve traditional design process </li></ul></ul><ul><ul><ul><li>Reduce prototyping costs </li></ul></ul></ul...
<ul><li>Rapid Manufacturing </li></ul><ul><ul><li>Reduced productions costs </li></ul></ul><ul><ul><li>Increase versatilit...
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10-10-05_04 Dan Larochelle: Rapid prototyping

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10-10-05_04 Dan Larochelle: Rapid prototyping

  1. 1. Rapid Prototyping Dan Larochelle Chief Technology Officer intelitek
  2. 2. <ul><li>Prototyping challenges the student to apply the fundamental concepts they learned in their STEM program </li></ul><ul><li>Prototyping is an essential part of the Engineering Design Cycle </li></ul><ul><li>Many students learn better with hands on projects and they are more likely to retain their knowledge and skills </li></ul>Why is Prototyping important to STEM?
  3. 3. <ul><li>Prototypes are an essential tool in product design </li></ul><ul><li>Prototypes are a way for students to express an idea </li></ul><ul><li>They can be simple or complex </li></ul><ul><li>They help answer the “3 F’s” – </li></ul><ul><ul><li>Fit </li></ul></ul><ul><ul><li>Form </li></ul></ul><ul><ul><li>Function </li></ul></ul>What is a Prototype?
  4. 4. Is this Rapid Prototyping?
  5. 5. <ul><li>Rapid Prototyping: </li></ul><ul><ul><li>Create something quickly </li></ul></ul><ul><li>ASTM International (2009) </li></ul><ul><ul><li>New Terminology adopted: </li></ul></ul><ul><ul><li>Additive Manufacturing </li></ul></ul><ul><ul><li>Subtractive Manufacturing </li></ul></ul>What is Rapid Prototyping?
  6. 6. <ul><li>Subtractive processes remove material from a solid workpiece and the result is the final part </li></ul><ul><li>Examples - </li></ul><ul><ul><li>Carving </li></ul></ul><ul><ul><li>Drilling </li></ul></ul><ul><ul><li>Milling </li></ul></ul><ul><ul><li>Turning </li></ul></ul><ul><ul><li>Grinding </li></ul></ul><ul><ul><li>Multi-axis Machining </li></ul></ul>Subtractive Manufacturing
  7. 7. CAD/CAM/CNC Process
  8. 8. <ul><li>Parts are made layer by layer </li></ul><ul><li>Each layer is a cross section of the part </li></ul><ul><li>derived from a three dimensional model </li></ul><ul><li>As the layers get thinner the accuracy of the part increases </li></ul><ul><li>Machines typically have a printing head on an XY motion system with a Z axis that moves the model as each layer is added </li></ul>Additive Manufacturing
  9. 9. <ul><li>Typical steps of the AM process: </li></ul><ul><ul><li>CAD </li></ul></ul><ul><ul><li>Convert to STL </li></ul></ul><ul><ul><li>Transfer to AM machine and manipulate STL file </li></ul></ul><ul><ul><li>Set up Machine </li></ul></ul><ul><ul><li>Build </li></ul></ul><ul><ul><li>Remove </li></ul></ul><ul><ul><li>Postprocessing </li></ul></ul><ul><ul><li>Application </li></ul></ul>Additive Manufacturing Process
  10. 10. <ul><li>A sheet of material is glued to the build platform </li></ul><ul><li>A pattern from the model is cut into the sheet and anti-glue is applied to areas of the sheet that are not part of the model </li></ul><ul><li>The next layer of material is glued on top of the previous layer forming a solid block of material </li></ul><ul><li>The support material is peeled away leaving the final product </li></ul>Laminated Object Manufacturing (LOM)
  11. 11. <ul><li>Material is fed to an extruding tip where is it melted into a fine stream to create the model layer by layer </li></ul><ul><li>Additional material is added to support the model during the build process </li></ul><ul><li>The support material can either be removed by hand or in a chemical bath </li></ul>Fused Deposition Modeling (FDM)
  12. 12. <ul><li>A very thin layer of powdered material is applied to the building platform </li></ul><ul><li>The printing head deposits a binding agent into the powder to form the desired shape </li></ul><ul><li>The part is removed from the powder and cleaned. The loose powder around the model also supports the model. </li></ul><ul><li>Parts can be multiple colors </li></ul>3D Inkjet Printing
  13. 13. <ul><li>A photo-sensitive resin is propelled through an extruding tip to build the part </li></ul><ul><li>As the jetting head distributes the resin it is simultaneously solidified by a UV lamp </li></ul><ul><li>Multiple materials can be used to construct the same part for added functionality or aesthetics </li></ul>Photopolymer Jetting
  14. 14. <ul><li>Thin coatings of photo-sensitive resin are solidified with a low powered UV light, electron beam or laser </li></ul><ul><li>As each layer of the model is built, the platform lowers and another layer of resin is added </li></ul><ul><li>Capable of creating high accuracy parts (+/- 0.002 of an inch) </li></ul>Stereolithography (SLA)
  15. 15. <ul><li>A photo-sensitive resin is sprayed onto the build platform layer by layer, similar to SLA </li></ul><ul><li>The machine produces an electrostatic mask to the model </li></ul><ul><li>The entire layer of the model is exposed to a UV light and hardens the unmasked area of the model </li></ul><ul><li>The masking is removed and process is repeated </li></ul>Solid Ground Curing (SGC)
  16. 16. <ul><li>A fine powder is propelled by an inert gas through a nozzle and melted by a high powered laser </li></ul><ul><li>Parts are non-porous and can be machined, sanded or ground after cooling </li></ul><ul><li>Parts may be built out of a wide range of metals and alloys like stainless steel, copper, aluminum and titanium </li></ul>Laser Powder Forming (LPF)
  17. 17. <ul><li>A very thin layer of material is applied to the building platform </li></ul><ul><li>A carbon dioxide laser melts the desired pattern into the material and another thin layer of material is added to the platform </li></ul><ul><li>After the part has cooled, it is removed from bed of powder </li></ul><ul><li>The material can be a thermoplastic, elastomer, nylon, metal, ceramic or sand </li></ul>Selective Laser Sintering (SLS)
  18. 18. <ul><ul><li>Improve traditional design process </li></ul></ul><ul><ul><ul><li>Reduce prototyping costs </li></ul></ul></ul><ul><ul><ul><li>Better communication of concepts </li></ul></ul></ul><ul><ul><ul><li>Get feedback earlier in the design process </li></ul></ul></ul><ul><ul><ul><li>Live model </li></ul></ul></ul><ul><li>Concurrent Engineering </li></ul><ul><ul><li>Reduce cycle time between iterations </li></ul></ul><ul><ul><li>Increase efficiency of design team </li></ul></ul><ul><li>Time to Market </li></ul><ul><ul><li>Decrease overall development time </li></ul></ul><ul><ul><li>Increase potential ROI </li></ul></ul>Benefits of Rapid Prototyping
  19. 19. <ul><li>Rapid Manufacturing </li></ul><ul><ul><li>Reduced productions costs </li></ul></ul><ul><ul><li>Increase versatility of product </li></ul></ul><ul><li>Micro/Nano Fabrication </li></ul><ul><ul><li>Produce microscopic parts </li></ul></ul><ul><ul><li>Currently being used in the electronics and medical industries </li></ul></ul><ul><li>Domestic Printing </li></ul><ul><ul><li>Technology becoming more and more user friendly </li></ul></ul><ul><ul><li>Printing personal items from home </li></ul></ul>The Future of Rapid Prototyping
  20. 20. Questions?

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