CHAPTER 19

Rapid-Prototyping Operations

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-1

Rapid Prototyping Examples

Figure 19.1 (a) Examples of parts made by rapid prototyping processes. (b) Stereolithography model of cellular phone.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

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Characteristics of Rapid Prototyping Technologies

TABLE 19.1 Supply phase Liquid Process Stereolithography Layer creation technique Liquid layer curing Phase change type Photopolymerization Materials Photopolymers (acrylates epoxies, colorable resins, filled resins) Photopolymers Polymers (ABS,polyacrylate, etc.) wax, metals and ceramics with binder. Polymers, wax Ceramic, polymer and me powders with binder. Polymers, metals with binder, metals, ceramics a sand with binder. Paper, polymers.

Solid-based curing Fused-deposition modeling

Liquid layer curing and milling Extrusion of melted polymer

Photopolymerization Solidification by cooling

Powder

Ballistic-particle manufacturing Three-dimensional printing Selective laser sintering

Droplet deposition Layer of powder and binder droplet deposition Layer of powder

Solidification by cooling No phase change

Solid

Laminated-object manufactuning

Deposition of sheet material

Laser driven sintering melting and solidification No phase change

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-3

Stereolithography

Figure 19.2 The computational steps in producing a stereolithography file. (a) Threedimensional description of part. (b) The part is divided into slices (only one in 10 is shown). (c) Support material is planned. (d) A set of tool directions is determined to manufacture each slice. Shown is the extruder path at section A-A from (c), for a fused-depositionmodeling operation.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-4

Fused-Deposition-Modeling
(a) (b)

Figure 19.3 (a) Schematic illustration of the fuseddeposition-modeling process. (b) The FDM 5000, a fused-deposition-modeling-machine. Source: Courtesy of Stratysis, Inc.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-5

Common Support Structures

Figure 19.4 (a) A part with a protruding section which requires support material. (b) Common support structures used in rapid-prototyping machines. Source: P.F. Jacobs, Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography. Society of Manufacturing Engineers, 1992.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-6

Stereolithography
Figure 19.5 Schematic illustration of the stereolithography process. Source: Ultra Violet Products, Inc.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-7

Example of Stereolithography
Figure 19.6 A twobutton computer mouse.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-8

Selective Laser Sintering

Figure 19.7 Schematic illustration of the selective laser sintering process. Source: After C. Deckard and P.F. McClure.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 19-9

Solid-Base Curing
Figure 19.8 Schematic illustration of the solid-base-curing process. Source: After M. Burns, Automated Fabrication, Prentice Hall, 1993.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-10

Three-Dimensional Printing
Figure 19.9 Schematic illustration of the threedimensionalprinting process. Source: After E. Sachs and M. Cima.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-11

Laminated-Object Manufacturing
(a) (b)

Figure 19.10 (a) Schematic illustration of the laminated-object-manufacturing process. Source: Helysis, Inc. (b) Crankshaft-part example made by LOM. Source: After L. Wood.

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-12

Investment Casting

Figure 19.11 Manufacturing steps for investment casting that uses rapid-prototyped wax parts as blanks. This approach uses a flask for the investment, but a shell method can also be used. Source: 3D Systems, Inc.
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 19-13

Sand Casting Using Rapid-Prototyped Patterns

Figure 19.12 Manufacturing steps in sand casting that uses rapid-prototyped patterns. Source: 3D Systems, Inc.
Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-14

Sand Casting (continued)

Figure 19.12
Kalpakjian Schmid Manufacturing Engineering and Technology 2001 Prentice-Hall Page 19-15

Rapid Tooling
Figure 19.13 Rapid tooling for a rearwiper-motor cover

Kalpakjian Schmid Manufacturing Engineering and Technology

2001 Prentice-Hall

Page 19-16