Technical Seminar

Topic : Rapid Prototyping

 INTRODUCTION

n Definition
n Rapid prototyping
n Stereo lithography
n Fused deposition modeling
n Laminated object manufacturing
n Selective laser sintering
n Plastic or polymer parts
n Silicon rubber tooling
n Investment casting
n Application of rapid prototyping
n Rapid prototyping equipments
n conclusion
What is manufacturing
process?
n The word manufacture is derived from two Latin words
“Manu” meaning by hand and “Factum” meaning almost
literally hand making

n Manufacturing is the conversion of

raw material into usable product
 RAPID

PROTOTYPING
Rapid Prototyping -
Definition
Rapid Prototyping (RP) is an
automatic process for
manufacturing objects directly
from their CAD models without
any cutters, tools or fixtures
specific to the object geometry.

It is more appropriate to call it

Layered Manufacturing or 3D
Printing or 3D Faxing.

n RP is a “divide-and-conquer”
manufacturing strategy.
 DRAWING
C
O
PROCESS N
R ENGINEERING V
A E
P N
I T
TOOL & FIXTURE I
D DESIGN O
N
P A
R CAD MODEL L
O MACHINING
T M
O A
T NO INTERMEDIATE C
INSPECTION H
Y STEPS
I
P N
I I
N N
G COMPLETED PART G
“TOOL LESS ADDITIVE PROCESS” TO CONVERT
CAD MODELS DIRECTLY INTO PHYSICAL PARTS
 What is Rapid Tooling ?

n Tool fabrication
techniques that use
layer wise Rapid
Prototyping
technologies -
directly or indirectly
 Rapid prototyping
Technologies
1. Stereo Lithography (SLA)
2. Fused Deposition Modeling (FDM)
3. Laminated Object Manufacturing (LOM)
4. Selective Laser Sintering (SLS)
5. Direct Metal Laser Sintering (DMLS)
6. Solid Ground Curing (SGC)
7. Laser Engineering Net Shaping (LENS)
 Rapid Prototyping – Input
materials

n SLA - Liquid epoxy resins

n FDM - ABS plastics
n LOM - Paper and Plastic sheets
n SLS - Polyamides and Metal powders
n DMLS - Polyamides and Metal powders
n LENS - Titanium, steel, inconel etc.,
Stereo lithography(SLA)
Part built by Stereo
lithography (SLA)
FDM (FUSED DEPOSITION
MODELLING)
 FDM Applications:
Functional Models
n Available Materials
n ABS
n ABSi
n Elastomer

n Key Part Characteristics

n ABS and ABSi closest RP
materials to engineering
thermoplastic ABS
n High Use Temperature =
>200 C
 FDM Systems

FDM 3000 FDM TITAN FDM VANTAGE

Part –LOM(LAMINATED
OBJECT MANUFACTURING)
Laminated Object
Manufacturing (LOM)

Parts are built by cutting Paper & Plastic sheet

INVESTMENT CASTING
n WAX CASTINGS OR MODELS FROM RP PROCESS ARE
ENCAPSULATED IN CERAMIC AND HEATED TO LEAVE A CAVITY
WHICH IS FILLED WITH METAL EITHER UNDER VACUUM
PRESSURE OR GRAVITY

n LEAD TIME LESS THAN 3 DAYS

n MATERIALS SUCH AS :
n MAGNESIUM
n ALUMINIUM
n BRONZE
n BRASS
n COPPER
n BERYLLIUM CAN BE CASTED
INVESTMENT CASTING
INVESTMENT CASTING
(Indirect tooling)
INVESTMENT CASTING
PATTERN
 Selective Laser-Sintering
Scanner Optics Laser
Loose
Powder

Part

Frame

Platform
Loose Powder
SILICONE RUBBER MOULDING
n TIME TO BUILD RP PART : 5 TO 50 HOURS
TIME TO FINISH A PART : 2 TO 8 HOURS
TIME TO MAKE A MOULD : 1 TO 4 HOURS
TIME TO CAST A PART : 1 HOUR

n PROCESS SUITABLE FOR PRODUCING 25 TO 100

PARTS
 Application

0F
Rapid prototyping
 Fine arts

Reproduction of a
fine detail plaque

Render showing
surface texture
 Jewellery

+ =
2,831,862 2,225,866
data points data points
• Scanning strategies
• Stylus 1.0mm ball
• Scanning speed 350mm/min
 Medical

Hip ball
93,414 points
Time 44mins
Hip socket
374,061 points
Time 3hr. 45mins
 Medical

• Scan time 4hr. 7min.

• 206,495 data points

• Scanning strategies
• Stylus 0.5mm ball
• Stepover 0.05mm
• Scanning speed 1000 mm/min.
 RAPID PROTOTYPING
EQUIPMENTS

SLA Viper si2 SLA 5000

SLA 7000
 In conclusion……
Ø RP , RE and RT technologies can reduce lead-time drastically for
product development.
Ø Reverse engineering technologies like CMM, standalone
scanning machines can help in capturing data of existing
product and thereby modifications can be done easily.
Ø RP(layering approach) allows very intricate parts to be
produced.
Ø A physical model that can be produced directly from CAD files,
can allow form, fit and function tests much earlier in the design
cycle.
Ø Prototype tooling manufacture for producing pilot batch for
functional trials and test marketing.
Ø New developments are going on in RP & RE technologies.
Thank You