Engineering Process 2 Mechanical Engineering University of Gaziantep

1. Chapter 20
Rapid-Prototyping Operations
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

2. Parts Made by Rapid-Prototyping
(a)
(b)
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
(c)
Figure 20.1 Examples of parts made by rapid-prototyping processes: (a) selection of
parts from fused-deposition modeling; (b) stereolithography model of cellular phone; and
(c) selection of parts form three-dimensional printing. Source: Courtesy of Stratasys, Inc.,
(b) and (c) Courtesy of 3D Systems, Inc.

3. Characteristics of Additive Rapid-Prototyping Technologies
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

4. Mechanical Properties of Selected Materials for Rapid
Prototyping
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

5. Computational
Steps in Rapid
Prototyping
Figure 20.2 The
computational steps in
producing a stereolithography
file. (a) Three-dimensional
description of each part. (b)
The part is divided 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. Also shown is the
extruder path at section A-A
from (c) for a fused-deposition-modeling
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
operation.

6. Fused-Deposition-Modeling
Figure 20.3 (a) Schematic illustration of the fused-deposition-modeling process. (b) The
FDM 5000, a fused-deposition-modeling machine. Source: Courtesy of Stratysis, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

7. Support Materials and Structures in Parts
Figure 20.4 (a) A part with a protruding section which requires support material.
(b) Common support structures used in rapid-prototyping machines. Source: P. F.
Jacobs, Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography.
Society of Manufacturing Engineers, 1992.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

8. Stereolithography
Figure 20.5 Schematic illustration of the stereolithography process.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

9. Two-Button Computer Mouse
Figure 20.6 A two-button computer mouse.
Source: Courtesy of 3D Systems, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

10. Selective-Laser-Sintering
Figure 20.7 Schematic illustration of the selective-laser-sintering process.
Source: After C. Deckard and P. F. McClure.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

11. Three-Dimensional-Printing
Figure 20.8 Schematic illustration of the three-dimensional-printing process.
Source: After E. Sachs and M. Cima.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

12. Three-Dimensional-Printing to Produce Metal Parts
Figure 20.9 Three-dimensional-printing using (a) part-build, (b) sinter, and (c) infiltration
steps to produce metal parts. (d) An example of a bronze-infiltrated stainless-steel part
produced through three-dimensional printing. Source: Courtesy of ProMetal.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

13. Fuselage Fitting Made by Three-Dimensional-Printing
(a)
(b)
Figure 20.10 A fitting required for a helicopter fuselage. (a) CAD representation with added
dimensions. (b) Dies produced by three-dimensional printing. (c) Final forged workpiece.
Source: Courtesy of ProMetal.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

14. Laminated-Object-Manufacturing
Figure 20.11 (a) Schematic illustration of the laminated-object-manufacturing
process. (b) Crankshaft-part examples made by LOM. Source: (a) Courtesy
of Helsis, Inc. (b) After L. Wood.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

15. Invisalign Orthodontic
Aligners
(a) (b)
Figure 20.12 (a) An aligner for orthodontic use manufactured using a combination of rapid
tooling and thermoforming. (b) Comparison of conventional orthodontic braces to the use
of transparent aligners. Source: Courtesy of Align Technologies, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

16. Manufacturing of Invisalign
Orthodontic Aligners
(a)
(b)
Figure 20.13 The manufacturing sequence for Invisalign orthodontic aligners. (a) Creation
of a polymer impression of the patient’s teeth. (b) Computer modeling to produce CAD
representations of desired tooth profiles. (c) Production of incremental models of desired
tooth movement. An aligner is produced by thermoforming a transparent plastic sheet
against this model. Source: Courtesy of Align Technologies, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
(c)

17. Investment Casting Using Rapid-Prototyped Wax Parts
Figure 20.14 Manufacturing steps for investment casting that uses rapid-prototyped wax
parts as blanks. This method uses a flask for the investment, but a shell method also can
be used. Source: Courtesy of 3D Systems, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.

18. Rapid Tooling for a Rear-Wiper Motor Cover
Figure 20.15 Rapid tooling for a rear-wiper motor cover.
Source: Courtesy of 3D Systems, Inc.
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. © 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.