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Page 1: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

Rapid Prototyping

Page 2: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 3: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 4: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 5: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 6: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology.

• used to produce models and prototype parts.

Page 7: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

Development

• Manual Prototyping by craftsman • 1970 prototyping in CAD , virtual environment• 1980, Rapid Prototyping (RP) by layer-by-layer

material deposition. CAD/CAM

Page 8: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 9: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 10: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 11: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 12: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 13: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 14: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• The standard data interface between CAD software and the machines is the STL file format.

• An STL file approximates the shape of a part or assembly using triangular facets.

• Smaller facets produce a higher quality surface.• SLC: Slice format, CLI: Common Layer Interface

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Page 17: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• Some solid freeform fabrication techniques use two materials in the course of constructing parts.

• The first material is the part material and the second is the support material (to support overhanging features during construction).

• The support material is later removed by heat or dissolved away with a solvent or water.

Page 18: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 19: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

Advantages during development ...No tooling costs

• Short production times• Comparatively low unit prices• Constructional simplification: e.g. instead of housing, lid and

screws, 1 complete sintered unit can be made• Test- and functional products can be produced in small

batches• Formal- and functional variants possible

Page 20: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

... production ...•

No tooling costs for small- and medium-sized batches• Low tooling costs for larger batches • Product customization possible without additional costs•

... and the production of spare parts.•

No tooling management necessary• Spare parts need no longer be kept but produced as required• Unlimited subsequent delivery

Page 22: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• Stereolithography (SL) is an additive manufacturing technology for producing models, prototypes, patterns, and in some cases, production parts.

• UV laser and liquid photo curable resin• Laser cures resin

Page 23: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 24: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
Page 25: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce
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Page 27: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• can be used as master patterns for injection molding, thermoforming, blow molding, and also in various metal casting processes

• Costly

Page 28: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• To create an SLA rapid prototype, first a three-dimensional CAD part is "sliced" horizontally into cross-sections between 0.002" and 0.006" thick.

• The slices are fed to 3D Systems' Stereolithography Apparatus. Inside the stereolithography chamber of the apparatus, an ultraviolet laser traces the first layer of the part on a metal platen, submerged just below the surface of a vat of photo-sensitive polymer.

Page 29: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• Wherever the laser touches the liquid, it solidifies. Once the layer is traced, the platen sinks the thickness of a layer below the level of the liquid.

• A sweeper bar moves across the surface of the last layer, making sure there is the exact amount of resin on top.

• The next layer is then built upon the previous layer. In this manner the entire part is built from the bottom up, with the completed sections of the part remaining submerged.

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Page 31: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• In the Selective Laser Sintering (SLS) process, three-dimensional parts are created by fusing (or sintering) powdered thermoplastic materials with the heat from an infrared laser beam.

• The object’s creation is accomplished by repeatedly fusing thin powder layers using a laser beam.

• This additive manufacturing sequence produces parts that gradually increase in size until they reach the prescribed dimensions.

• These prototypes are created directly from 3D CAD models.

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Page 33: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• Selective laser sintering is an additive manufacturing technique that uses a high power laser (for example, a carbon dioxide laser) to fuse small particles of plastic, metal (Direct Metal Laser Sintering), ceramic, or glass powders into a mass representing a desired 3-dimensional object

Page 34: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

powder

• polymers (nylon, also glass-filled or with other fillers, and polystyrene), metals (steel, titanium, alloy mixtures, and composites) and green sand.

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Page 37: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• A plastic filament or metal wire is unwound from a coil and supplies material to an extrusion nozzle which can turn on and off the flow.

• The nozzle is heated to melt the material and can be moved in both horizontal and vertical directions by a numerically controlled mechanism,

Page 38: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• The model or part is produced by extruding small beads of thermoplastic material to form layers as the material hardens immediately after extrusion from the nozzle.

• acrylonitrile butadiene styrene (ABS) polymer, the FDM technology can also be used withpolycarbonates, polycaprolactone, polyphenylsulfones and waxes.

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Page 41: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• In it, layers of adhesive-coated paper, plastic, or metal laminates are successively glued together and cut to shape with a knife or laser cutter.

Page 42: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

• The process is performed as follows:1. Sheet is adhered to a substrate with a heated

roller.2. Laser traces desired dimensions of prototype.3. Laser cross hatches non-part area to facilitate

waste removal.4. Platform with completed layer moves down out

of the way.5. Fresh sheet of material is rolled into position.6. Platform moves up into position to receive next

layer.7. The process is repeated.

Page 43: Rapid Prototyping. Rapid prototyping is the automatic construction of physical objects using additive manufacturing technology. used to produce

Features

• Low cost due to readily available raw material• Dimensional accuracy is slightly less than that

of Stereolithography and Selective laser sintering but no milling step is necessary.

• Relatively large parts may be made, because no chemical reaction is necessary