useful for B.Tech students

1. Additive Manufacturing
Rapid Prototyping
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Dr.B.Sudarshan
Associate professor
MED,KSRMCE,KADAPA

2. Our Objectives
• To increase the efficiency of MSMEs in the Northern
Region in the light engineering and allied fields.
• To provide training in Tool and Die Technology,
CAD/CAM Solutions.
• To design and manufacture Quality Press Tools,
Moulds & Dies, Jigs & Fixtures and Gauges.
• To provide Consultancy for Total Tooling Solutions,
Product development, Reverse engineering,
Productivity & Quality Improvement.

3. Activity Areas
• Product and Tool Design
• Rapid Prototyping
• Production
• Heat Treatment
• Quality Control
• Consultancy
• Training

4. Rapid Prototyping
Rapid Prototyping : Technology For Design Validation
Advantages:
 Design Validation without investment in Tooling
 Number of Iterations possible.
 Product validation well before commencement of Tool
Design.
 Provide physical simulation in real Time Environment.
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5. Rapid Prototyping &
Manufacturing
• Rapid prototyping (RP) refers to the physical modeling of a design
using a special class of machine technology.
• RP systems produces prototype parts from 3D CAD (computer-
aided design) data, CT , MRI scan data, or data created from any 3D
digitizing systems.
• RP uses Additive Fabrication approach for building shapes.
• RP systems produces parts layer by layer in paper, wax, plastics,
ceramic, and metal parts.
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6. Rapid Prototyping Process Steps
Creation of the CAD model of Design
Conversion of CAD Model into STL format
Slicing of STL file into thin sections
Building part layer by layer
Post processing/finishing/joining 6

7. COMPONENT OF RP SYSTEM
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8. Advantages of Rapid Prototyping
1. Promote the innovation of new products and accelerate conceptual
design and final production of sample and test products.
2. Allow more product variation while making only minor changes
on the original product or making assembly of different product
features. Allow building more prototypes and test more options.
3. Achieve higher productivity because product goes from 3-D CAD
design to finished part in one step.
4. Ability to produce any product feature without considering the
limitations of machine tools or jigs. IF the product can be digitally
produced by CAD software, it should physically be produced by RP.
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9. 5. Products go fast and first to market in very short time and gain
marketing rewards, “Short time to market”.
6. Cost-effective production because of directly manufacturing of
customized short production runs without wasting money, labor,
energy and machining time in large production batches.
7. “Spare Parts on Demand” and “Production on Demand” which
saves production cost and storage space that are needed to produce
spare parts and production stock.
8. Fully automation and seamless process integration from handling
of raw material to finished part.
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10. Major RP Technologies
• Stereolithography Laser Apparatus (SLA)
• Selective Laser Sintering (SLS)
• Selective Laser Melting(SLM)
• 3Dimensional Printing
•Inkjet or Multijet Modeling
•Fused Deposition Modeling(FDM)
• Thermo jet Process
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11. SLA
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12. SLA
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13. SLA Material
ABS-Like
ABS-like, Black
ABS-like, Gray
Durable
High Resolution
High Temp PC-Like, Rigid
High-Impact ABS-Like
High-Temp ABS-Like
PE-Like (Somos 8110)
PP-Like (Accura 25 / VisiJet SL Flex)
Rigid, PC-Like
Semi-flexible
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14. SLA Material Properties
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15. SLA Material Properties
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16. Stereolithography (SLA)
STRENGTHS
Best Feature Resolution
Accuracy
Surface Finish
Fast
WEAKNESSES
Material
Handling
Support requirement
Part stacking not possible
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17. SLS
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18. SLS
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19. Criteria for material selection in SLS
Comparison of mechanical properties
SI- Unit Duraform
PA
Duraform
GF
PP ABS PA6.6
Tensile Strength Mpa 44 38 32-37 32-45 65
Tensile Modulus Mpa 1600 5910 1300 2400 2000
Elongation at break % 22 2 650 20 150
Flexural Modulas Mpa 1285 3300
Impact Strength
Notched Izode
J/m 216 60 300
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20. Metal Sintering in SLS
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21. Selective Laser Sintering (SLS)
STRENGTHS
Accuracy
Feature Detail
Most flexibility in part geometry
Materials
Economical for assembly of parts
WEAKNESSES
Precision
Powder handling
Part warping
Expensive for small parts
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22. 3D Printing
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23. 3D Printing (3DP)
STRENGTHS
 FASTEST
 MOST ECONOMICAL
 COLOUR
WEAKNESSES
 Accuracy
 Limited material choice
 Strength
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24. INKJET/Multi jet Modeling
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25. Polyjet Material
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26. Polyjet Material
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27. INKJET/Multi jet Modeling
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28. FDM
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29. FDM MATERIAL
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30. Fused Deposition Modeling (FDM)
STRENGTHS
 Ease of Use
 ABS Material
 Handling
 Economical for Small Parts
WEAKNESSES
 Slow
 Accuracy
 Limited material choice
 Surface finish
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31. Vacuum Casting
CUSTOMER
3D CAD DATA
RAPID
PROTOYPYE M/C
JOINING/
FINISHING/
PAINTING OF
MASTER PART
FINISHING/
PAINTING
EXTRACTING
PU CASTED
COMPONENTS
POLYURETHANE
RESIN
POURING
CURING
EXTRACTING
MASTER PART
CUTTING OF
MOULD ALONG
PARTING LINE
CURING
SILICON
POURING
MOULD
PREPERATION
PACKING AND
DESPATCH
ACTUAL
COMPONENT IN ANY
MATERIAL
Flowchart:
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32. 32
Vacuum Casting Services
Mould size :750x900x750mm
Silicon mould life: Typically 20 pcs
Materials: Thermo set plastics similar to
ABS, Nylon, Polycarbonate (PC),
Polypropylene (PP), Elastomers
Surface Finish: Surface finish
comparable to injection moulding.
Clear parts: Water clear parts for see-thru
applications in fully
transparent or translucent finishes.
Insert Moulding: Threaded inserts, studs,
brackets, wires or any
custom parts can be fully encapsulated in
the material.

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Vacuum Casting

34. Process Comparison
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35. Process Comparison
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36. Requirement SLA Epoxy SLS Nylon FDM ABS 3DP
Tight Tolerance Best Fair Good Poor
Large Parts Depends on Machine Size
Speed Good Best, when lot of
parts combined
Best, for small
parts
EXCELLENT
Marketing Models Best Good Fair EXCELLENT
Few Small Parts Good Fair Best Poor
Snap Fit Parts Poor Best Good Poor
Living Hinges Poor Best Good Poor
Bottles Fair Best Good Excellent
Limited
Functionality
Poor Best Good Poor
Thin Walled Parts Best Good Poor Poor
Chemical
Resistance
Poor Good Good Fair
Masters for
Rubber Moulds
Best Fair Good Fair for large parts
Direct Investment
Casting Patterns
QuickCast: Fair Polystyrene: Best ABS: Poor Poor
RP Selection
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37. Areas of Application of RP
• Concept Model
• Models for market research
• Rapid Tooling
• Models for Stress analysis
• Fine Arts
• Industrial Design and Architectural Modeling
• Jewelry Design
• Medical
• Dentistry
• Anthropology
• Archeology
• Forensics 37

38. •Automotive Industry 37%
•White goods and Consumer products 17%
•Office Equipment 10%
•Medical applications 7%
•Aerospace 7%
•Defence and Govt. Sectors 7%
•Institutions 7%
•Others 8%
Industry segment wise usage
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39. RP Facility at CTR
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40. RP Facility at CTR
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41. 41
Prototype Parts of Scooter
Complete scooter Body made on SLS Machine

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Rapid Prototyping Centre
Some Prototype Parts of Washing Machine
Spinning Basket
Base
Base
Washing Machine
Pulsator
All Items made in parts,then joined & finished

43. Schematic of the Medical Modeling
RP Process
CT/MRI SCAN
Data
Data Processing
Using Specialized
Software
R P
Machine
3D
Physical
Model
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44. •Technology : Selective Laser Sintering (SLS)
•Material : Laser form ST-100
•Application : Prototype Tool Inserts,Bridge
tooling, Functional metal prototypes
RP - Application
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45. Obstacles to RP Growth
Rapid prototyping is not immune to the wide ranging obstacles that limit the
growth of new products and technology.
1. Early adopters are few and far between.: The vast majority of people and
companies prefer technology and applications that are fully developed and mature; in
other words, without risk.
2. Computer-based modeling and prototyping : Computer modeling, such as CAD
solid modeling, is needed to help expand the RP market. Interestingly, it also is a factor
that will increasingly limit RP's growth.
3. Too costly: common misconception is that RP is expensive. Depending upon the
situation, this can be true. Yet, there are scores of applications where RP is a less
expensive solution.
4. Resistance to change: It is surprising how people cling to the past and avoid change.
Indeed, old habits die hard. Supported by the lack of adoption, it is safe for companies to
continue developing products in the same manner that they have used for years.
5.Lack of awareness: Most engineering and manufacturing professionals know of RP,
but many are not fully aware of its power and implications.
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46. Research Areas
1. Process Development
2. Materials of Construction
3. Equipment Development
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47. Materials of Construction
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48. Needs of AM
• Variety in material
• Cost competitive material
• Improved Speed of construction
• Capital cost of machine
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49. Thank you !