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RAPIDPROTOTYPING

INTRODUCTIONOFRPT

Rapid Prototyping (RPT) can be defined as An approximation of a product (or system) or its components in some form for a definite purpose in its implementation. Rapidprototypingisthemostcommonnamegiventoahostofrelatedtechnologies that are used to fabricate physical objects directly from cad data source. These methodsuniqueinthattheyaddandbondmaterialsinlayerstoformobjects. Rapid prototyping is different from traditional fabrication in that it is only possible through the use of computers, both to generate the 3D CAD model data, as well as tocontrolthemechanicalsystemofthemachinethatbuildthepart. Virtually all RP processes additives parts are build up by adding depositing or solidifying one or more materials in a horizontal layer wise process. The part is builduplayerbylayeruntildone. This is similar to the result one would get if one made a topographical map of the object,withthecounterlinesrepresentingthelayerthicknessoftheprocess. The materials which are available for RP use will depend on the process chosen andarestillrelativelylimited,butthevarietyisgrowing. There are number of plastics and resins commonly used, as well as some processes thatcanusethinlikestarch,plaster,waxandmetal. Therapidactuallyreferstothereducedtimefrominitialdesigntotheproduction ofthefinalpart. This is due to the elimination of extensive amounts of hand and machine work involvedinmakingprototypes. SuchTechnologyisknownbydifferentterms,suchas DesktopManufacturing ToollessManufacturing 3DPrinting LayerManufacturing FreeFormFabrication(F3)

RPTTECHNIQUE

IntheRapidPrototypingprocessthe3DCADdataisslicedintothincrosssectional planesbyacomputer. The cross sections are sent from the computer to the rapid prototyping machine whichbuildsthepartlayerbylayer. The first layer geometry is defined by the shape of the first cross sectional plane generatedbythecomputer. It is bonded to a starting base and additional layers are bonded on the top of the firstshapedaccordingtotheirrespectivecrosssectionalplanes. Thisprocessisrepeateduntiltheprototypeiscomplete.
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WHYRPTREQUIRED?

Visualization DesignChange(iterations) FreeFormPrototyping(complexobjectfabrication) TestingFit/Packaging Cost,Time,andresourceestimation ProcessPlanning FirsttoMarketCriticalfortodaysindustry Rapidproduction(concurrentactivities) JITconcept(0Inventory) Rapidtooling/notoolingtrendintechnology ConcurrentEngineering LimitedProduction

Designverification Designformanufacturability Designforassembly Designformaintainability Designforreliability DesignforQuality DesignParameters(Tolerances/allowances) Tooling ReverseEngineering Diefabrication ToolPathgeneration

ADVANTAGESOFRPT

Noplanningofprocesssequences Nospecificequipmentforhandlingmaterials Notransportationbetweenmachining Featuresbaseddesignandfeaturerecognitionareunnecessary Definingablankgeometryisunnecessary Defining different setups or complex sequences of handling material is unnecessary Noneedtoconsiderjigsandfixtures Designingandmanufacturingmouldsanddies Highqualityproductiseasilydelivered Enablesdevelopmenttimeandcosts

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DISADVANTAGESOFRPT

Specificmaterialsarerestricted Failsinreplicationoftherealproductorsystem Maynotbesuitableforlargesizecomponents Manyproblemsareoverlookedresultinginendlessrectificationsandrevisions Some important developmental steps could be omitted to get a quick and cheap workingmodel The user may have very high expectations about the prototypes performance and thedesignerisunabletodeliverthese

APPLICATIONOFRPT

ManufacturingofcomponentsusingFunctionallyGradientMaterials(FGM). Assemblieswithoutjoints. Componentsdifficultbyothermanufacturingprocesses. Rapid prototypes act as concept model for better visualization and communication. Marketing personnel can use rapid prototypes to assess the aesthetic appeal of the productbydisplayingtheminshowrooms. RPcanbeusedforform,fitandfunctionaltest. Forstressanalysis. Forwindtunneltest. Itcanbesubmittedalongwiththequotations.

ROLEOFRPT
Productdesign Increasepartcomplexityanddiversitywithlittleeffectonleadtimeandcost Minimise timeconsuming discussion and evaluations of manufacturing possibilities Tooldesignandmanufacturing Minimisedesign,manufacturingandverificationoftooling Reducepartscountandeliminatetoolwear

Assemblyandtest Reduce labour content of manufacturing (e.g. machining, casting, inspection andassembly,etc.) Reduce material costs (e.g. handling, waste, transportation, spare and inventory,etc.) Functiontesting
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Avoiddesignmisinterpretations,i.e.whatyoudesigniswhatget)

CLASSIFICATIONOFRPT

LiquidBased

StereoLithographyApparatus(SLA) SolidGroundCuring(SGC) SolidCreationSystem(SCS) SolidObjectUltravioletLaserPrinter(SOUP) LightSculpting Aaroflex RapidFreeze TwoLaserBeams Microfabrication

SolidBased

LaminatedObjectManufacturing(LOM) FusedDepositionModeling(FDM) PaperLaminationTechnology(PLT) MultiJetModelingSystem(MJM) ModelMakerandPatternMaster SlicingSolidManufacturing(SSM) MeltedExtrusionModeling(MEM) MultiFunctionalRPMSystems(MRPM)

PowderBased

SelectiveLaserSintering(SLS) SelectivePowderBindingORThreeDimensionalPrinting(3DP) LaserEngineeredNetShaping(LENS) DirectShellProductionCasting(DSPC) MultiphaseJetSolidification(MJS) ElectronBeamMelting(EBM) DirectMetalDeposition(DMD)

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StereoLithographyApparatus(SLA)

StereoLithographyisthemostwidelyusedrapidprototypingtechnology. Stereo Lithography builds plastic parts or objects one layer at a time by tracing a layer beam on the surface of a vat of liquid photopolymer, inside of which is a moveablestagetosupportthepartbeingbuilt. The photopolymer quickly solidifies wherever the laser beam strikes the surface of the liquid. Once one layer is completely traced, the stage is lowered a small distanceintothevatandasecondlayeristraceddirectlyontopofthefirst. Theselfadhesivepropertyofthematerialcausedeachsucceedinglayertobondto the previous one and thus form a complete, three dimensional object out of many layer. Objects which have over hang or undercut must be supported during the fabricationprocessbysupportstructure. Uponcompletionofthefabricationprocess,theobjectisremovedfromthevatand thesupportsarecutorbrokenoff.

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ADVANTAGES: Possibility of manufacturing parts which are impossible to be produced conventionallyinasingleprocess Canbefullyatomizedandnosupervisionisrequired. HighResolution Nogeometriclimitations DISADVANTAGES: Necessitytohaveasupportstructure Requirelaborforpostprocessingandcleaning APPLICATION: Modelsforconceptualization,packagingandpresentation Prototypesfordesign,analysis,verificationandfunctionaltesting Mastersforprototypetoolingandlowvolumeproductiontooling Patternsforinvestmentcasting,sandcastingandmoulding Toolsforfixtureandtoolingdesignandproductiontooling
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SelectiveLaserSintering(SLS)

In this method, thermoplastic powder is spread by a roller over the surface of a buildcylinder.Thepistoninthecylindermovesdownoneobjectthicknesslayerto accommodatethenewlayerofpowder. Another piston moves upward incrementally to supply a measured quantity of powderforeachlayer. A laser beam is traced over the surface of this tightly compacted powder to selectivelymeltandweldthegrainstogethertoformalayeroftheobject. The fabrication chamber is maintained at a temperature just below the melting point of the powder so that the laser elevates the temperature slightly to cause sintering,whichgreatlyspeedsuptheprocess. The process is repeated, layer by layer, until the entire object is formed. After the object,thepistonisraised. Excess powder is simply brushed away and final manual finishing may be carried out. It takes a considerable cooldown time before the part can be removed from the machine. Large parts with thin sections may require as much as two days of cooling.

ADVANTAGES:

SLS offers the key advantage of making large sized functional parts in essentiallyfinalmaterials. Materialpropertiescanbequiteclosetothoseoftheintrinsicmaterials.
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DISADVANTAGES: The system is mechanically more complex than stereo lithography and most othertechnologies. Surfacefinishesandaccuracyarenotasgoodaswithsteriolithography. Sincetheobjectsaresinteredtheyareporous. APPLICATION: Conceptmodels Functionalmodelsandworkingprototypes Waxcastingpattern Polycarbonate patterns. These build faster than wax patterns and are ideally suited for design with thin walls and fine features. These pattern are also durableandheatresistant Metal Tools. Direct rapid prototype of tools of moulds for small or short productionruns.

SelectivePowderBindingORThreeDimensional Printing(3DP)

(1) Powderlayerisdeposited (2) Inkjetprintingofareasthatwillbecomethepart (3) Pistonisloweredfornextlayer(v=motion) Parts are created by a layered printing process and adhesive bonding, based on sliced cross section data. A layer is created by adding another layer of powder. The powder layer is selectively joined, where the part is to be form, by inkjet printing ofablindermaterial Theprocessof3DPismoreefficientandrelativelycheaperthansinteringtypes.

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Platform is located at the height necessary for a layer of ceramic powder to be deposited. Platform is located at the height necessary for a layer of ceramic powder to be deposited Theplatformisloweredbythelayer thickness to permit a new layer of powder to bedeposited The new layer is scanned, conforming it to the shape of the next upper cross sectionandadheringittothepreviouslayer. ADVANTAGES: Highspeed Simpletooperate Nowastageofmaterials Full24bitpaletteofcolors To produce parts with a variety of material properties to serve a range of modelingrequirements DISADVANTAGES: Limitedfunctionalparts Limitedmaterials Poorsurfacefinish APPLICATION: CADCasting metal parts: A ceramic shell with integral cores can be fabricateddirectlyfromtheCADmodel Direct metal parts: It is adaptable to a variety of material systems, allowing theproductionofmetallic/ceramicpartswithnovelcomposition Prototypeswithcoloursandelasticfeature

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FusedDepositionModeling(FDM)

FDM is the second most widely used rapid prototyping technology, after stereo Lithography. A plastic filament is unwound from a coil and supplies material to an extrusion nozzle. The nozzle is heated to melt the plastic and has a mechanism which allows the flowofthemeltedplastictobeturnedonandoff. The nozzle is mounted to an XY plotter type mechanism which trace out the part counter. There is a second extrusion nozzle for the support material (different from the modelmaterial). As the nozzle is moved over the table in the required geometry it deposits a thin beadofextrudedplastictoforeachlayer. Theplastichardensimmediatelyafterbeingsquirtedfromthenozzleandbondsto thelayerbelow. Theobjectisbuiltonamechanicalstagewhichmovesvirtuallydownwardlayerby layerasthepartisformed.Theentiresystemiscontainedwithinachamberwhich isheldatatemperaturejustbelowthemeltingpointoftheplastic.
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ADVANTAGES:

Themethodisofficefriendlyandquiet. FDMisfairlyfastforsmallpartsontheorderofafewcubiccentimeters. Thepartsaremorerobust. DISADVANTAGES: Itcanbeveryslowforlargepartswithalotofvolume. Depending on the part geometry and orientation, it can also require more supportmaterialthanthepartitself(orvirtuallynone). The finished parts exhibit different mechanical characteristics in different directions.resolutionisnotasfineaswithstereoLithography.

APPLICATION: Modelsforconceptualizationandpresentation Prototypesfordesign,analysisandfunctionaltesting Patternsandmastersfortooling.Modelscanbeusedaspatternsforinvestment casting,sandcastingandmoulding

LaminatedObjectManufacturing(LOM)

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LMO actually works by cutting the slice of the object out of a sheet of a paper foil andbondingthemtogether. The foil comes of the material supply roll and the laser then cuts around the outline of the layer, it also hatches the foil around the edges so that this can be easilybrokenawaywhenallofthelayershavebeenbondedtogether. A sensor is used to measure the thickness of the foil and the machine will automaticallyadjustthedimensionsofthelayerbeingcut. After the laser has cut out the top layer, a heated roller moves over the top of the foiltobondthelayertotherestoftheobject. ADVANTAGES: Material cost are very low, and objects have the look and feel of wood and can beworkedandfinishedinthesamemanner Processisfasterthanotherprocesses Nointernalstressandundesirabledeformations LOMcandealwithdiscontinuities,whereobjectsarenotclosedcompletely
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DISADVANTAGES: In general, the finish, accuracy and dimensional stability of paper objects are notasgoodasformaterialsusedwithotherRPmethods. In,additionthelasercuttingofthematerialcreatesalotofsmokeandneedsto theoutside. Thestabilityoftheobjectisbondedbythestrengthofthegluedlayers. PartswiththinwallsinthezdirectioncannotbemadeusingLOM HollowpartscannotbebuiltusingLOM APPLICATION: Applicableforawiderangeofproduct,equipmentforaerospaceorautomotive, consumerproducts,andmedicaldevices Prototypesfordesign,analysisandfunctionaltesting Toolsforproduction Smallvolumeoffinishedgoods

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