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INDEX
• Introduction of Rapid Prototyping
• Basic principle and methodology
• Various Techniques of RP
• Applications of RP
• Advantages and Disadvantages
• Future scope for development
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INTRODUCTION
• Prototype – A replica or model for testing
conceptualized design
• Manual fabrication and testing is now old practice
• New quick technique- Rapid Prototyping
• Definition- A group of techniques used to quickly
fabricate a scale model of a part or assembly using
three-dimensional computer aided design (CAD)
data.
• Characteristics of RP:
1.A RP model free-form manufacturing
2.layered manufacturing method
(i.e. layer by layer additive process)
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BASIC PRINCIPLE OF WORKING OF RP
Basic principle involves 5 steps:
• Creation of the CAD model of the design
• Conversion of the CAD model to STL format
• Slicing the STL file into 2-D cross-sectional layers
• Layer by layer construction
• Cleaning and finishing the model
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Creation of the CAD model of the design
•Drafting 3-D model on software
•Softwares include CATIA,PRO-E, Auto-Desk etc
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Conversion of the CAD model to STL format.
•STL (Stereolethography format)
•Surfaces are divided into no. of triangles
•Fixing coordinates of the vertices of all triangular
parts
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Slicing the STL file into thin cross-sectional layers
•Slicing the model in layers from 0.01 to 0.7mm
•Generating an auxiliary structure to support the model
during the build.
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Layer by layer construction of model
•Building one layer at a time from polymers, paper, or
powdered metal
•Layer by Layer completes the whole model
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Cleaning and finishing the model
• Removing the prototype from the machine
• Detaching any supports
• Cleaning, finishing etc
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VARIOUS TECHNIQUES OF RP
• Stereo-lithography Process
• Selective Laser Sintering(SLS)
• Laminated Object Manufacturing(LOM)
• Fused Deposition Modeling(FDM)
• 3-D Ink-Jet Printing
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Stereolithography Process
• Patented in 1986
• Solidification of liquid photosensitive polymers
when exposed to UV light
• Exposing next layer to UV with lowering
platform by elevator
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Selective Laser Sintering(SLS)
• Patented in 1989
•Powdered materials like
nylon, elastomers are
used
• Sintering of powder
takes place when exposed
to UV
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Laminated Object Manufacturing(LOM)
• Developed in 1985 by Hydronetics in Chicago
• Paper laminated with heat-activated glue is used
• A focused laser cuts the outline of the first layer
into the paper
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Fused Deposition Modeling(FDM)
• Developed in 1988 by S. Scott Crump
• Feeding thermoplastic filament wire
• Deposition of heated plastic layer by layer to
complete the part
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3-D Printing
• Developed in MIT & licensed to Soligen Corporation,
• An ink-jet printing head selectively deposits(prints) a
binder fluid to fuse the powder together in the
desired areas.
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APPLICATIONS OF RP
• Engineering
• Complex parts of Aerospace industries
• Rapid Tooling
• Architecture
• Medical Applications
• Tooth and bone implants
• Hearing instruments
• Arts and Archaeology
• Statues and ornaments
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ADVANTAGES & DISADVANTAGES
Advantages:
• Faster production of parts
• Less expensive
• Helps in quick testing of product
• Fast error elimination and assists product
developments
• Low labor cost
• Reduction in material cost, waste disposal cost,
inventory cost, material transportation cost
• Quick design modification
• Better communication between the designer and
user
Disadvantages:
• High machinery cost
• Unsuitability to very large product
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Future scope for developments in RP
• Improving speed
• Improved accuracy and surface finish.
• Use of metal and composite materials
• Increasing size capacity
• Distance Manufacturing on Demand(being
developed by Researchers at UC-Berkeley)
