The document presents an overview of rapid prototyping, detailing its definition, basic processes, advantages, and disadvantages. It compares additive manufacturing with traditional machining, emphasizing its efficiency, time savings, and cost-effectiveness in product development. Additionally, it discusses various prototyping techniques, applications, and future developments, highlighting the technology's potential to revolutionize manufacturing in various industries.

1. Unit -6(b)
RAPID PROTOTYPING
Presented By
Dr. Sivasankara Raju R
Associate Professor
Dept. of Mechanical Engg.
AITAM, Tekkali-532201
Andhra Pradesh

2. CONTENTS
 What is Rapid Prototyping
 Basic process of RP
 Prototyping of processes:
1. Stereolithography
2. Fused Deposition Modeling
3. Laminated Object Manufacturing
 Advantages & disadvantages of above processes.
 Applications
 Future development
 Conclusion
 References

3. Prototype Fabrication
Techniques
Laser Cutting
Waterjet Cutting
EDM
EB
CNC machining
Subtractive Additive
SLA,
SLS,
FDM,
Direct Casting
LOM
Laser
Bending
Electromagnetic Forming,
Adaptive Die Casting,
Casting,
Forging
Formative

4. History of RP

5. What is Additive
Manufacturing?
• Additive Manufacturing is a method in which the part
is created by a layer- additive process.
• Using a specialized software, a 3-D CAD model is cut
into very thin layers or cross-sections.
• Then, depending on the specific method used
(sintering, fused deposition, etc), the AM machine
constructs the part layer by layer until a solid replica
of the CAD model is generated.
• The advantages of this process is clear: development
of physical models can be accomplished in
significantly less time as compared to the machining
process.
• Machining is a subtractive process, beginning with a
solid piece of stock. The machinist must carefully
remove material until the desired geometry is
achieved. For complex part geometries, this is an
exhaustive, time consuming, and expensive

6. Trends in manufacturing industries
emphasis the following
 Increasing the no of variants of
products.
 Increase in product complexity.
 Decrease in product lifetime before
obsolescence.
 Decrease in delivery time.
 Product development by Rapid
prototyping by enabling better
communication.

7. Conventional Machining
 Its not suitable for complex shapes because they
are difficult to machine.
 Time consuming
 Very costly
 Tedious or very laborious.
 Skilled operator is required.
 Accuracy will be less.
 Increased product development time.

8. Advantages of AM
 Rapid Prototyping can give with concept proof that
would be needed for attracting funds.
 The Prototype hints the user about the final product look
.
 It can increase early visibility.
 Easy to find design flaws in the early stages of
developmental.
 Active participation among the users and producer is
encouraged.
 It is cost effective,as development cost reduces.
 Any deficiency in the earlier prototypes can be detected
and rectified in time.
 There is better communication between the user and

9. Disadvantages Of Rapid
Prototyping
 It fails in exact replication of the real product or system.
 Some important developmental steps might get omitted
to get a quick and cheap working model. This turns out
to be one of the greatest disadvantages of rapid
prototyping.
 Another disadvantage is that many problems are
overlooked resulting in endless corrections and
revisions.
 Unsuitable for large sized applications.
 Compared to user’s high expectations, the prototype’s
performance and the designer are unable to deliver
these.
 The producer may produce an inadequate system that
is unable to meet the overall demands of the

10. AM for Product Development
Process
Concept
Development
System-Level
Design
Detail
Design
Testing &
Refinement
Production
Ramp-Up
Concept
Development
System-Level
Design
Detail
Design
Production
Ramp-Up
Testing &
Refinement

11. Input
• Physical Objects
• CAD Models
• STL Files
• Sliced Model Files
Material
Paper, Resins, Nylon, ABS,
Wax, metals, ceramics
•Liquid
•Powder
•Solid
Method
• Photocuring
• Cutting&Gluing
• Melting&Solidifying
• Binding
Applications
• Design
•Engineering, Analysis &Planning
•Manufacturing &Tooling
RP

12. Create a CAD model of the design
Convert the CAD model to
STL format
Slice the STL file into layers
Construct the physical model
layer by layer
Clean and finish the model
Computed Tomography
Scan
The tessellated

13. 1. What is Rapid Prototyping
Rapid Prototyping: Traditional manufacturing:
additive material subtractive material

14. Build
Prototype
BASIC PROCESS OF RP
Three stages: pre-processing, building, and
post processing
RP Process Post Process
Pre Process
Generate
.STL file
Build Supports
if needed
Slicing
Remove
Supports
Clean
Surface
Post Cure if needed
Part Completed
CAD Model
Surface/Solid
Model
in RP
systems
in CAD

15. Commonly Used Terms for
Additive Manufacturing
• Rapid Prototyping (RP)
• Direct CAD Manufacturing
• Desktop Manufacturing
• Instant Manufacturing
• CAD Oriented Manufacturing
• Layer Manufacturing
• Material Deposit Manufacturing
• Material Addition Manufacturing
• Solid Freeforming

16. Advantages of AM
• Reduce product
development time and cost
• Get products to market
sooner
• Enhance communications
between marketing,
engineering,
manufacturing, and
purchasing
• Present physical model at
critical design reviews
• Perform functional
prototype testing before
committing to tooling
• Generate precise
• Staircase effect
• Layer thickness
• Accuracy
• Part orientation
• Support Structures
Issues in Layered-Based
Manufacturing

17. PROTOTYPING PROCESSES

18. AM Processes
Material Basic Process Process Name
Solid
Laminated Object Manufacturing
(LOM)
Fused Deposition Manufacturing
(FDM)
Gluing Sheets
Melting+Solidification
Powder
Selective Laser Sintering
(SLS)
3D Printing
Material powder
Material+Binder
Liquid
Solid Ground Curing
(SGC)
Stereolithography
(SLA)
Liquid
Polymerization

19. 2.1 Stereo-Lithography (SL)
1. The elevator lowered by
1 layer deep;
2. The Blade sweep across
the vat, apply an even
layer of resin on top of the
part;
3. As the laser beam strikes
the resin surface, the
liquid resin is hardened to
a solid plastic;
4. Loop through the three
steps to cure a new layer.

21. Advantages Disadvantages
 Parts have best
surface quality
 High Accuracy
 High speed
 Finely detailed
features like thin
vertical walls, sharp
corners & tall
columns can be
fabricated with ease.
 It requires Post
Processing. i.e.
Post Curing.
 Careful handling of
raw materials
required.
 High cost of Photo
Curable Resin
Applications:
Investment Casting.
Wind Tunnel Modeling.
Tooling.
Injection Mould Tools.

22. Materials:
Photocurable resins:
 acrylate
 polyurethane
 Build Materials Used:
 Epoxy Resin, Acrylate
Resin
 Epoxy Resin has better
material properties and
less hazardous but
require large exposure
time for curing.

23. 2.2 Fused Deposition Modeling (FDM)
1. Extrusion head and
elevator move to start
position;
2. The head extrude
layer of support;
3. The head extrude
layer of model;
4. Loop through the three
steps to build the next
layer.

24. fused-deposition-modeling-fdm-
technology-givefastlink

26. Materials:
thermoplastic material
 wax
 polycarbonate
 elastomer
-
Advantages:
•Strength and temperature
capability of build materials.
•Safe laser free operation.
•Easy Post Processing.
Disadvantages
•Process is slower than
laser based systems.
•Build Speed is low.
•Thin vertical column prove
difficult to build with FDM.
•Physical contact with
extrusion can sometimes
topple or at least shift thin
vertical columns and walls.

27. 2.4 Laminated Object Manufacturing
(LOM)
1. The sheet material is
stretched from the supply
roller to the take-up roller;
2. The heated laminated
roller passes over the
sheet bonding it to the
previous layer;
3. Laser cuts the profile of
that layer and hatching
the excess material for
later removal;
4. Loop through the three
steps to form a new layer.

28. lom-process-from-helisys-givefastlink

29. Materials:
 Sheet material:
 paper
 plastic
 ceramic composite etc.

30. Selective Laser Sintering (SLS)
Applications:
1. As conceptual
models.
2. Functional
prototypes.
3. As Pattern masters.
sls-3d-printing-technology-givefastlink
how-does-selective-laser-sintering-
sls-work-givefastlink

31.  Advantages:
1. Wide range of build materials.
2. High throughput capabilities.
3. Self supporting build envelop.
4. Parts are completed faster.
5. Damage is less.
6. Less wastage of material.
Disadvantages:
1. Initial cost of system is high.
2. High operational and
maintenance cost.
3. Peripheral and facility

32. 3. Application cases of RP
Common applications
of the RP technology:
 Design
concept models
 Medical application
Computer
Tomography - CT
scanner

33.  Marketing
models for tenders,
customer feedback,
presentations and
brochures
 Rapid prototyping is
widely used in the
automotives.
AUDI RSQ

34.  ADVANTAGES:
 Reduced the time.
 Accuracy is
increased.
 Parts can be used
immediately after the
process and no post
curing is required.
 DISADVANTAGES:
 Although there is
some choice of
materials including
paper, plastic,
ceramic and
composite, we can
not used metal as a
material to create
prototype.

35. Applications of AM
 Design
• CAD model verification
• Visualizing objects
• Proof of concept
• Market and
presentation application
 Manufacturing and Tooling
• Tooling mold parts (soft
tooling and hard tooling)
• Casting
• EDM electrodes
• Master models
Engineering Analysis and Planning
• Form and fit
• Stress analysis
• Mock-up parts
• Pre-production parts
• Diagnostic and surgical
operation planning
Industries
• Aerospace
• Jewelry
• Consumer electronics
• Automotive
• Biomedical
• Tableware

36. •One such improvement is increased speed of part building
“Rapid" prototyping machines.
• Another future development is improved accuracy and
surface finish.
•The introduction of non-polymeric materials, including metals,
ceramics, and composites, represents another much
anticipated development. These materials would allow RP
users to produce functional parts.
•Another important development is increased size capacity
Advances in computerized path planning, numeric control,
and machine dynamics are increasing the speed and
accuracy of machining.
Future development:

37. CONCLUSION
After studying the rapid prototyping we can
conclude that the process(RP) is really a
efficient , flexible process with better scope in
future as compared to old prototyping
techniques. It necessiates rapid production of
prototype in less time and cost.

38. Reference
www.wikipedia.in/rapidprototyping
 S.H. Ahn, M. Montero, D. Odell, S.
Roundy,
P.K. Wright, Anisotropic material
properties of
fused deposition modeling ABS,
Rapid
Prototyping J. 8 (4) (2002) 248–257.
 K. Thrimurthulu, P.M. Pandey,
N.Venkata
Reddy, Optimum part deposition
orientation in