Rapid prototyping is a technology that enables quick creation and evaluation of prototypes from CAD data, primarily utilizing additive manufacturing techniques. It has applications in various industries such as aerospace, automotive, biomedical, and fashion, facilitating effective communication, reduced development time, and minimized costly mistakes. The process involves creating a digital model, slicing it into layers, and building the prototype layer by layer using different methods including stereo lithography and selective laser sintering.

1. RAPID
PROTOTYPING
MANOJ K
1ST SEM
M.TECH (CIM)
TECHNICAL SEMINA

2. INTRODUCTION
 Revolutionary and powerful technology with
wide range of application.
 The process involve quick building up of a
prototype or working model for the purpose of
testing the various design features, ideas,
concepts, functionality, output and performance.
 Group of techniques used to quickly fabricate
a scale model of a part or assembly using 3D
CAD data.
 RP is an "additive" process, most machining
processes are "subtractive" processes
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3. HISTORY
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 In 60’s, first RPT became accessible.
 In 70’s, Herbert Voelcker, engineering professor
developed the basic tools of mathematics that
describe the 3D aspects.
 In 80’s
 Carl Deckard ,researcher from the University of Texas.
 He pioneered the layer based manufacturing, he thought
of building up the model layer by layer.
 He printed 3D models by utilizing laser light for fusing
metal powder in solid prototypes, single layer at a time.
 Technique called ‘Selective Laser Sintering’.
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4. HISTORY(Cont...)
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 Nowadays
 The computer engineer has to simply sketch the
ideas on the computer screen with the help of a
design program.
 CAD allows to make modification as required and
can create a physical prototype that is a precise and
proper 3D object.
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5. WHAT IS RAPID
PROTOTYPING?5
 “Process of quickly
building and
evaluating a series of
prototypes"
 Early
 Throughout the
design process
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6. WHY RAPID PROTOTYPING?
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 Effective communication.
 Development time.
 Costly mistakes.
 To minimize sustaining engineering changes.
 To extend product lifetime by adding
necessary features
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7. Cont…
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 The trends in manufacturing industries
continue to emphasize the following:
 Increasing number of variants of products.
 Increasing product complexity.
 Increasing product lifetime.
 Decreasing delivery time.
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8. HOW DOES RP WORK?
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 The process begins with taking a virtual design
from modelling or CAD software.
 The 3D printing machine reads the data from
the CAD drawing
 lays down successive layers of liquid, powder,
or sheet material — building up the physical
model from a series of cross sections.
 These layers are automatically joined together
to create the final shape.
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9. APPLICATIONS
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1. RAPID TOOLING
 Patterns for Sand Casting
 Patterns for Investment
Casting
 Pattern for Injection
moldings
2. RAPID MANUFACTURING
 Short productions runs
 Custom made parts
 On-Demand Manufacturing
 Manufacturing of very
complex shapes
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3. AEROSPACE & MARINE
 Wind tunnel models
 Functional prototypes
 Boeing’s On-Demand-
Manufacturing
4. AUTOMOTIVE RP SERVICES
 Production level
 Reduced time to market
 Functional testing
 Dies & Molds

10. Cont…
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5. BIOMEDICAL
APPLICATIONS
 Prosthetic parts
 Presurgical planning
models
 Mechanical bone replicas
 Anthropology
 Forensics
7. ARCHITECTURE
 3D visualization of design
space
 Iterations of shape
 Sectioned models
6. FASHION &
JEWELRY
 Shoe Design
 Jewellery
 Pattern for lost wax
 Other castings

11. BASIC PROCESS
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Create a CAD model of the design
 Object to be built is modelled using CAD software.
 Solid modellers like Pro-E yield better results.
 Existing CAD file may also be used
Convert the CAD model to STL (Standard
Tessellation Language) format
 STL format is the standard of rapid prototyping industry.
 This format represent 3D surface as an assembly of planar
triangles and describes only surface geometry.

12. Cont…
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Slice the STL file into thin cross-sectional layers
 Several programmes are available for this.
 STL models are sliced into a number of layers (.01mm to .7mm).
 Orientation size and location are adjusted using the software.
Construct the model one layer atop another
 RP machine builds one layer at a time from polymers, paper, or
powdered metal.
 Fairly autonomous needing little human intervention.
Clean and finish the model
 Post processing step.
 Prototype may require minor cleaning and surface treatment.

13. RP TECHNIQUES
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Most commercially available rapid prototyping
machines use one of the four techniques
 Stereo lithography (SL or SLA).
 Laminated object manufacturing.
 Selective Laser Sintering.
 3D ink jet printing.

14. STEREO LITHOGRAPHY(SL)
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 Builds 3D model from liquid photo sensitive polymers when exposed to UV rays.
 Model is built upon a platform situated just below the surface of liquid epoxy or acrylate
resin.
 A low power highly focused UV laser traces out the first layer, solidifying model cross
section.
 An elevator incrementally lowers the platform into the liquid polymer.
 Process is repeated until prototype is complete.
 Model is the placed in an UV oven for complete curing.

15. Cont…
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16. Laminated Object Manufacturing
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 Layer of adhesive coated sheet materials are bonded to form a prototype.
 Paper laminated with heat activated glue is rolled up on spools.
 Heated roller applies pressure to bond the paper to the base.
 Feeder/collector mechanism advances paper.
 Laser cuts the outline of first layer.
 Platform is lowered and fresh material is advanced.
 Process is repeated and a roller bonds the layers.

17. Cont…
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18. SELECTIVE LASER SINTERING
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 Uses laser beam to selectively fuse powdered
materials such as nylon, elastomer or metal into a
solid object.
 Parts are built on a platform which sits below the
surface in a bin of heat fusible powder.
 Laser traces the pattern of first layer, sintering it
together.
 Then platform is lowered, powder is reapplied and
process is repeated.

19. Cont…
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20. 3D INK JET PRINTING
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 Parts are built upon a platform situated in a bin full of powder material.
 An ink-jet printing head selectively deposits or "prints" a binder fluid to
fuse the powder together in the desired areas.
 Unbound powder remains to support the part.
 The platform is lowered, more powder added and levelled, and the process
repeated.
 Finished parts can be infiltrated with wax, glue, or other sealants to
improve durability and surface finish.
 Typical l
 ayer thicknesses are on the order of 0.1 mm.
 This process is very fast, and produces parts with a slightly grainy surface.
 There are also other different types of 3d printing available in the market
which gives very good accuracy.

21. Cont…
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22. ADVANTAGES
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 Accuracy
 Product complexity
 Minimal wastage
 No part supports required
 High speed

23. DISADVANTAGE
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 Not suitable for large sized applications.
 Limited materials
 Poor Surface finish
 High machine cost

24. CONCLUSION
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 Modern CNC machines have high removal rates which helps
in fast machining.
 For certain applications machining will continue to be a useful
manufacturing process.
 One should regard RPT as one more option in the toolkit for
manufacturing parts.
 No tooling: less tools is better
 One shot operation: no assembly of parts
 Reduce lead time: less time improve production rate
 Flexible: modification, addition of parameters, scaling
 Clean & safe operation

25. REFERENCES
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 Rapid Manufacturing, Flham D.T & Dingoy
S.S Verlog London 2001.
 Rapid Prototyping, Terry Wohlers Wohler’s
Report 2000” Wholers Association 2000.

26. THANK YOU
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