2/18/2014

What is: Rapid Prototyping? Rapid Prototyping

FTMD ITB 2014
Rapid prototyping is a computer program that constructs three-dimensional models of work derived from a Computer Aided Design (CAD) drawing.
Rapid prototyping takes virtual designs from computer aided design (CAD) or animation modeling software, transforms them into cross sections, still virtual, and then creates each cross section in physical space, one after the next until the model is finished. It is a process where the virtual model and the physical model correspond almost identically.

Products of Rapid Prototyping

Advantages of Rapid Prototyping

CAD data files can be manufactured in hours. Tool for visualization and concept verification. Prototype used in subsequent manufacturing operations to obtain final part Tooling for manufacturing operations can be produced

2/18/2014

RP Sequence
CAD solid model .STL file Slicing the file Final build file Fabrication of part Post processing

CAD Solid Model

Solid model or closed surface model required

.STL File
Software generates a tessellated object description File consists of the X, Y, Z coordinates of the three vertices of each surface triangle, with an index to describe the orientation of the surface normal Support generation to hold overhung surfaces during build

.STL File
solid ascii facet normal 0.000000e+000 -1.018113e-001 -9.948037e-001 outer loop vertex 6.413766e+000 9.540946e+000 4.174942e-001 vertex 6.663766e+000 9.540946e+000 4.174942e-001 vertex 6.413766e+000 9.467294e+000 4.250320e-001 endloop endfacet facet normal 1.587419e-015 -1.018113e-001 -9.948037e-001 outer loop vertex 6.413766e+000 9.467294e+000 4.250320e-001 vertex 6.663766e+000 9.540946e+000 4.174942e-001 vertex 6.663766e+000 9.467294e+000 4.250320e-001 endloop endfacet . .

2/18/2014

Types of Rapid Prototyping Machines

Selective Laser Sintering (SLS) Fused Deposition Modeling (FDM) Stereolithography (SLA) Laminated Object Manufacturing (LOM) Laser Engineered Net Shaping (LENS) Electron Beam Melting (EBM) 3D Printing (3DP) Multi Jet Modeling (MJM) CNC Milling (CNC)

Selective laser sintering

SLS based on sintering of nonmetallic powders onto a selective individual objects Basic elements in this process are bottom of processing chambers equipped with 2 or 3 cylinders Powder feed cylinder which is raised incrementally to supply powder to part-build cylinder through a roller mechanism Part-build cylinder which is lowered incrementally to where the sintered part is formed.

Selective laser sintering

Set of the proper computer files and the initiation of the production processes Machine operate unattended and provide rough part after few hours Finishing operations as sanding and painting Labor intensive & production time varies from few minutes to few hours

Selective laser sintering

Layer of powder is first deposited on part build cylinders A laser beam controlled by instruction from 3-D file is focused on that layer tracing & sintering a particular crosssection into a solid mass & dust is taken off. Another layer of powder is now deposited this cycle is repeated again and dust is shaken off

2/18/2014

Selective laser sintering

Selective laser sintering

DTM, Austin, TX, now 3D systems patent 1989, Carl Deckards masters thesis fusing polymeric powders with CO2 laser accuracy 160 mm

no supports polycarbonate, nylon, wax, glass-filled nylon, powder coated metals or ceramics can be end-use parts

Selective laser sintering

Fused Deposition Modeling

A gantry robot controlled extruder head moves in two principle directions over a table Table can be raised or lowered as needed Thermo plastic or wax filament is extruded through the small orifice of heated die Initial layer placed on a foam foundation with a constant rate Extruder head follows a predetermined path from the file After first layer the table is lowered and subsequent layers are formed
Fig : (a)Fused-deposition-modeling process. (b)The FDM 5000, a fused-decompositionmodeling-machine.

2/18/2014

Fused Deposition Modeling

Stratasys, Eden Prarie, MN patent 1992 robotically guided fiber extrusion accuracy 0.005 casting and machinable waxes, polyolefin, ABS water soluble or wax supports

Fused Deposition Modeling

Fig: a)A part with protruding section which requires support material b) Common support structures used in rapid-prototyping machines

Works based on the principle of curing liquid photomer into specific shape A vat which can be lowered and raised filled with photocurable liquid acrylate polymer Laser generating U-V beam is focused in x-y directions The beam cures the portion of photo polymer and produces a solid body Now the platform is lowered by a slice Then another portion of the cylinder is shaped till the portion is reached

Stereolithiography

Stereolithography (SLA)
3D Systems, Valencia, CA patent 1986, beginning of RP photopolymerization using UV laser epoxies, acrylates (brittle) excellent accuracy < 50 mm

relatively slow $179,000 (103 in3) to $799,000 (203 in3)

2/18/2014

Laminated object manufacturing

Laminated implies laying down of layers which are adhesively bonded to one another Uses layer of paper or plastic sheets with heat activated glue on one side of the product parts Excess material to be removed manually Simplified by preparing the laser to burn perforations in crosssectional pattern LOM uses sheets as thin as 0.05mm Compressed paper has appearance and strength of soft wood , and often mistaken for elaborate wood carvings.

Laminated object manufacturing

3D Printing
ZCorpSanders Prototype Inc., NH ink jet technology dual heads deposit part material (thermoplastic) and support material (wax) build layers as thin as .0005 very fast and cheap process

3D Printing

2/18/2014

Laser Engineered Net Shaping TM

In development (Sandia Labs, Optomec) Fully Dense Metal parts with good metallurgical properties Laser melts metal powder Powder delivered coaxially with laser Inert gas protects weld pool Near net shape with some finish machining

Laser Engineered Net Shaping TM

http://home.att.net/~castleisland/sgc.htm

Kenneth G. Cooper, Rapid Prototyping Technology, Selection and Aplication, Marcel Dekker, Inc.