mdmd 512 - rapid product developmentstaff.frederick.ac.cy/eng.la/mdmd512 rapid product...rapid...
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Rapid Product Development MDMD 512
MDMD 512 - Rapid Product Development
Dr.-Eng. Antonios Lontos
Department of Mechanical Engineering
School of Engineering and Applied Sciences
Frederick University
7 Y. Frederickou Str., Nicosia 1036, Cyprus
E-mail: [email protected], [email protected]
Web: http://staff.fit.ac.cy/eng.la
MSc in Manufacturing and Welding Engineering Design
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Table of Contents
Chapter 01: Introduction
Chapter 02: Rapid product development and tools
Chapter 03: Rapid prototyping technologies
Chapter 04: Laser scanners and computer tomography
Chapter 05: Reverse engineering
Chapter 06: Rapid tooling
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Learning outcomes of the course unit
• Discussing the wide variety of new rapid prototyping technologies such as liquid or solid based rapid
prototyping systems.
• Apply rapid prototyping technologies in product development
• Be able to use 3D printing, stereolithography, selective laser sintering, and fused deposition modeling to the
product development process.
• Be able to design, optimize, manufacture, and validate a physical system component.
• Use additive manufacturing as an automated technique for direct conversion of 3D CAD data into physical
objects using a variety of approaches
• Be able to select the appropriate rapid prototyping technology in the automotive, aerospace, medical, and
consumer products industries
Introduction - About the course
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Course contents:
• Rapid Prototyping process. Process chain, 3D Shape Technologies, 3D modelling, Software Engineering,
Digital Representation of Shapes, 3D laser scanners and surface generation, Computer tomography and
Solid creation, Different algorithms to represent solid objects. Rapid prototyping data formats, Data
conversion and transmission, Postprocessing.
• Rapid Prototyping Techniques. Stereolithography, Three-dimensional models from liquid photosensitive
polymers, Stereolithography apparatus (SLA) machines, Laminated Object Manufacturing, adhesive-coated
sheet material, Selective Laser Sintering, Laser beams, Fused Deposition Modeling, Solid Ground Curing, 3-
D Ink-Jet Printing
• Liquid, solid and powder based rapid prototyping. 3D Systems, Models and specifications, Processes and
principles, Microfabrication, Deposition Manufacturing process.
• Applications of Rapid Prototyping. Applications in design, engineering, Analysis and planning, Applications in
manufacturing and tooling, Aerospace, automotive, biomedical, Jewellery industry.
• Future Developments. Technical evaluation through benchmarking, Industrial growth, Accuracy improvement
and surface finish, Use of new materials like non-polymeric materials, metals, ceramics and composites,
Distance Manufacturing on Demand, Further developments trends.
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Recommended and/or required reading
1. Rapid prototyping, Principles and applications,
2. Additive Manufacturing Technologies, Gibson Ian, Rosen David, Springer, New York, 2010
3. Chua C.K, Leong K.F, Lim C.S, Rapid Prototyping Principles and Applications, World Scientific, New
Jersey, 2005
4. Bartolo, Jorge Paulo, Virtual and Rapid Manufacturing, Taylor And Francis, London, 2008
5. Manufacturing Engineering and technology, Six Edition, Serope Kalpakjian, Steven R. Schmid, Prentice
Hall
6. Manufacturing Processes for Engineering Materials, Fifth Edition, Serope Kalpakjian, Steven R. Schmid,
Prentice Hall
Course Assignment
• Real rapid product development problem
Assessment method
• Assignments: 100%
Introduction - About the course
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Assessment methods and criteria
Assignments: 100%
GRADE: A (86-100), B (76-85), C (66-75), D (56-65), E (50-55)
Introduction - About the course
Description – Assessment Grade (%)
1. Effort - Time spent on project 10
2. Writing skills - Is the writing text adequate? English language, text format,
pictures, drawing, diagrams 10
3. Main body - Extensive, accurate and appropriate details 40
4. Methodical approach to the design and manufacturing development. Good
approach of the designing methods and manufacturing processes 10
5. Enthusiastic - The student was interested about his work 5
6. Conclusion and results - Are the final results and conclusions well defined
and analytically explained? 5
7. Learning outcome - The scientific and professional skill of the student was
increased during the elaboration of the project? 10
8. Overall quality - What is the overall quality of the project? 10
Overall 100%
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Aims
To produce engineering designers with "concurrent engineering" capability, integrating materials and
manufacturing process selection into a structured design methodology based on the application of basic
engineering and scientific principles. Emphasis on design creativity.
Outline
• Design Communication (CAD, solid modelling)
• Design Methodology (design process, customer focus, integration of engineering science)
• Prototyping (processes and their selection, materials selection, costs)
Introduction - About the course
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End of Chapter
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Rapid Product Development MDMD 512
MSc in Manufacturing and Welding Engineering Design
MDMD 512 - Rapid Product Development
1. Introduction
Dr. Antonios Lontos Website: http://staff.fit.ac.cy/eng.la/
E-mail: [email protected], [email protected]
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• Rapid Product Development will prepare students for entry-level jobs in the drafting industry.
• Learn how products are brought to market – from concept to the finished product.
• Use 3D CAD software to design their product and transform the virtual design to a physical
object using rapid manufacturing processes.
• Included sketching, drafting, design, and 3D computer applications on PC computer systems
using SolidWorks software and 3D printers that produce rapid prototype models.
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Meet the needs of specialized applications, including:
Design Prototypes
3D print concept models, functional prototypes and presentation models for evaluating and
refining designs, including finite element analysis (FEA) results and packaging.
Education
Engage students by bringing digital concepts, into the real world, turning their ideas into
real-life 3D color models that they can actually hold in their hands.
Architecture
Create models of architectural designs and prototypes for the design of critical elements.
Industrial
Make patterns and molds for metal casting, RTV molding and urethane casting applications.
Entertainment and the Arts
Produce custom avatars and figurines from 3D data generated by electronic games — and other
creations — with ease.
Geospatial
Easily convert GIS data into 3D landscape and cityscape models.
Healthcare
Rapidly produce 3D models to reduce operating time, enhance patient and physician
communications, and improve patient outcomes.
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3D Systems, producers of the world’s fastest, easiest-to-use and most affordable color 3D printers,
Produce physical color models quickly, easily and inexpensively from computer-aided design (CAD)
and other digital data. The most successful companies have adopted 3D printing as a critical part of
the iterative design process to:
Increase Innovation
• Print prototypes in hours, obtain feedback, refine designs and repeat the cycle until designs
are perfect
• Create affordable prototypes early in the ideation stage of product development
Improve Communication
• Hold realistic 3D models in your hands to impart infinitely more information than a computer
image
• Communicate with various audiences using fast, affordable and easy 3D printing
Speed Time to Market
• Compress design cycles by 3D printing multiple prototypes on demand, right in your office
Reduce development Costs
• Cut traditional prototyping and tooling costs
• Identify design errors earlier
• Reduce travel to production facilities
Win Business
• Bring realistic 3D models to prospective accounts, sponsors and focus groups
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3D printer Advantages
High speed and throughput for a range of applications
• Output models in hours, not days
• Build multiple models at the same time
• Support an entire engineering department or classroom with ease
Color and high quality dramatically communicate design intent
• Produce realistic color models without paint
• Better evaluate the look, feel, and style of product designs
• 3D print text labels, logos, design comments, or images directly onto models
• A range of options, from 64 basic colors to unlimited color combinations
• Multiple print heads provide the best range of accurate and consistent colors high resolution
Realistic models and precise details
• High-definition 3D printing produces models with complex geometries and small, detailed
features
• 3D print the most intricate detail, such as a thin wall on a mechanical prototype or a railing on
an architectural model
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Affordable for all environments
• Unused materials are recycled for the next build, eliminating waste
• Based on reliable, affordable inkjet technology
Spend time generating ideas, not operating a 3D printer
• Requires minimal training and expertise
• Only ZPrinters perform most operations automatically
• Automated setup and self monitoring
• Automated powder loading and recycling
• Snap-in binder cartridges
• Intuitive control panel for easy operation
Ideal for everyday use in any standard office or school environment
• Quiet, safe, odor free
• Closed-loop powder loading, removal, and recycling
• Eco-friendly, non-hazardous build material
• No physical support structures to remove with dangerous cutting tools or toxic chemicals
• Noise-suppression technologies for quiet, intrusion-free operation
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Various RP Methods
• Photo curing
• Cutting and joining
• Melting
• Solidifying / fusing
• Joining / binding
Materials
• Solid
• Liquid
• powder
Applications
• Design
• Engineering analysis and planning
• Tooling and manufacturing
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Advances of rapid prototyping
Direct benefits (experiment with physical objects)
Benefits to Product Designers
Increase part complexity with less time and cost
Benefits to the tooling and manufacturing Engineers
Savings in cost. Minimize design, manufacturing and verification of tooling
Benefits of marketing
New capabilities and opportunities
Benefits to the consumers
Special products to customers needs. Products built to order.
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