1) Rapid prototyping is a manufacturing process that builds 3D objects using additive processes where layers of material are joined under computer control. 2) There are three main types of rapid prototyping technologies - liquid-based, solid-based, and powder-based - which differ in the initial state of the build material and how layers are joined. 3) The benefits of rapid prototyping include reduced lead times and costs for complex parts, greater design freedom, and lower tooling costs compared to traditional manufacturing methods.

1. FORMING &
SHAPING
LECTURE BY:
N U R H U D A H A Y A T I B I N T I
M O H A M A D Y A Z I
E X T 1 8 2
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2. Rapid prototyping
PART 3/3 – 5.3
SECTION 5.3
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3. RAPID PROTOTYPING
 INTRODUCTION TO RAPID PROTOTYPING
 FUNDAMENTALS OF RAPID PROTOTYPING
 ADVANTAGES OF RAPID PROTOTYPING
SECTION 5.3
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4. RAPID PROTOTYPING
 CLASSIFICATION OF RP TECHNOLOGIES
➢ LIQUID BASED
➢ SOLID BASED
➢ POWDER BASED
SECTION 5.3
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5. Rapid Prototyping can be divided into two basic
categories:
Subtractive: Material removal process
Additive: Material addition process
SECTION 5.3.1
Introduction to Rapid Prototyping
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6. SUBTRACTIVE TECHNOLOGIES
SUBTRACTIVE
• The machine starts out with a block
of plastic or wax and uses a
delicate cutting tool to carve away
material, layer by layer to match
the digital object.
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7. SUBTRACTIVE TECHNOLOGIES
SUBTRACTIVE
• Older and less efficient.
• Similar to a computer numerical control (CNC)
device such as lathe or a mill
• Complex shapes and forms with undercuts are
more difficult to accomplish
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8. ADDITIVE TECHNOLOGIES
ADDITIVE
• The machine reads data from a
CAD drawing, and lays down layers
of liquid plastic, powdered plastic
or some other engineering material,
and builds up the model from a
long series of cross sections.
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9. ADDITIVE TECHNOLOGIES
ADDITIVE
• These layers glued together or fused
(often using a laser) automatically to
create the final shape.
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10. ADDITIVE TECHNOLOGIES
ADDITIVE
• Because RP technologies are being increasingly
used in non-prototyping applications, such
systems are also known by the general names
- Freeform fabrication (FFF)
- Solid freeform fabrication (SFF)
- layered manufacturing
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11. DEFINITION
RP
Definition of Rapid Prototyping
A number of additive or
subtractive
directly
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12. I. Modeled on a CAD/CAM
II. Model converted into a format “STL”
(STereoLithography)
III. Analyzes STL into cross sections (Preprocessing)
IV. File transfer to machine
SECTION 5.3.2
Fundamentals of Rapid Prototyping
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13. V. Build process until model accomplished
VI. Post processing: removal of the part from the machine,
as well as any necessary support removal and sanding
or finishing
SECTION 5.3.2
Fundamentals of Rapid Prototyping
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14. 14

15. SECTION 5.3.3
Advantages of Rapid Prototyping
Benefits to Product Designers
Benefits to Tooling & Manufacturing
Engineer
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16. Benefits to Product
Designers
Section 5.3.3.1
✓ Little effects on lead time & cost with
increase in part complexity
✓ Few constraints in the form of parts
design
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17. Benefits to Product
Designers
Section 5.3.3.1
✓ Optimize part design to meet customer
needs
✓ Can produce product that not easily
set up for machining
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18. Benefits to Tooling and
Manufacturing Engineers
Section 5.3.3.2
✓cost saving for tooling
✓minimize design, manufacturing &
verification of tooling
✓prototype as master pattern for tooling &
manufacturing 18

19. SECTION 5.3.4
Classification of RP Technologies
Liquid Based
Solid Based
Powder Based
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20. LIQUID BASED
Section 5.3.4.1
P R O C E S S D E S C R I P T I O N
E X A M P L E S
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21. Liquid Based
 Initial material in liquid state
 Liquid is converted into solid state by
curing process
 Method: photo curing
➢ Single laser beam
➢ Masked lamp
Section 5.3.4.1
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22. Stereolithography
Apparatus (SLA)
Single Laser Beam
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23. Solid Ground Curing (SGC)
Masked Lamp
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24. SOLID BASED
Section 5.3.4.2
P R O C E S S D E S C R I P T I O N
E X A M P L E S
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25. Solid Based
 All material in solid state
 In form of wire, a roll, laminates & pallets
 Method:
➢ Cutting & gluing/joining
➢ Melting & Solidifying/Fusing
Section 5.3.4.2
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26. Laminated Object
Manufacturing (LOM)
Cutting & gluing/joining
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27. Fused Deposition Modeling
(FDM)
Melting & Solidifying/Fusing
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28. POWDER BASED
Section 5.3.4.3
P R O C E S S D E S C R I P T I O N
E X A M P L E S
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29. Powder Based
 Material in solid state in grain-like form
 Produce solid model by joining / binding
method
 Method of joining:
➢ Laser joining
➢ Binder / glue to achieve joining effect
Section 5.3.4.3
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30. Selective Laser Sintering
(SLS)
Laser Joining
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31. 3D Printing
Binder/glue to achieve joining effect
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32. THE END of
C H A P T E R 5