RAPID PROTOTYPING OF DIE CASTING,

INVESTMENT CASTING COMPONENTS IN

INDUSTRY

Guided By
Prof. D.V. Shirbhate

Submitted By
Ashish B. Agrawal
Sudhir D. Godle
Ku. Vaishali R. Joshi
Mangesh H. Kambekar
 Scope of Project
• The project work is assigned by Professor D.S.
Ingole, Assistant Professor, Department of
Production Engineering, College of Engineering and
Technology Badnera.
• The work consist of developing the rapid prototype
model of Maruti 800 and investment, die casting
components of Jadhav Steel and Alloys
• The Company have hard copy drawing which needs
to e converted into solid models for better
understanding and rapid prototyping
 Method by which project work is carried out
Step 1
Drawing reading
Step 2
Learning of CATIA software to develop the model.
Step 3
Conversion of CAT format into STL format for rapid
prototyping
Step 4
Developing rapid prototype model by FMD process
 Introduction to Rapid Prototyping
The term Rapid Prototyping (RP) refers to a
class of technologies that can automatically
construct physical models from Computer-Aided
Design (CAD) data. These "three dimensional
printers" allow designers to quickly create tangible
prototypes of their designs, rather than just two-
dimensional pictures. Such models have
numerous uses. They make excellent visual aids
for communicating ideas with co-workers or
customers. In addition, prototypes can be used for
design testing. The technique are often collectively
refer to as solid free form fabrication CAM or
layered manufacturing
 Rapid Prototyping Techniques
• Stereolithography
• Laminated object manufacturing
• Selective laser sintering
• Fused deposition modeling
• Solid ground curing
• Ink-Jet printing
 Stereolithography
Patented in 1986, stereolithography started the
rapid prototyping revolution. The Stereolithography
process is the most widely used of all Rapid
Prototyping processes in the year 2004.
The technique builds three-dimensional models
from liquid photosensitive polymers that solidify
when exposed to ultraviolet light. As shown in the
figure below, the model is built upon a platform
situated just below the surface in a vat of liquid
epoxy or acrylate resin. A low-power highly focused
UV laser traces out the first layer, solidifying the
model’s cross section while leaving excess areas
liquid.
 Schematic diagram of stereolithography
HeCd laser
Lenses

Mirror

Elevator

Liquid
polymer
HeNe laser
Platform
 Laminated Object Manufacturing

In this technique, developed by Helisys of

Torrance, CA, layers of adhesive-coated sheet
material are bonded together to form a prototype.
The original material consists of paper laminated
with heat-activated glue and rolled up on spools.
As shown in the figure below, a feeder/collector
mechanism advances the sheet over the build
platform, where a base has been constructed
from paper and double-sided foam tape. Next, a
heated roller applies pressure to bond the paper
to the base. A focused laser cuts the outline of
the first layer into the paper and then cross-
hatches the excess area
 Laser

Mirror
Heated roller
Optical head

Platform
Feeder
Collector

Schematic diagram of laminated object manufacturing.

 Selective Laser Sintering

Developed by Carl Deckard for his master’s

thesis at the University of Texas, selective laser
sintering was patented in 1989. The technique,
shown in Figure, uses a laser beam to selectively
fuse powdered materials, such as nylon, elastomer,
and metal, into a solid object. Parts are built upon a
platform which sits just below the surface in a bin
of the heat-fusable powder. A laser traces the
pattern of the first layer, sintering it together. The
platform is lowered by the height of the next layer
and powder is reapplied.
Schematic Diagram of Selective Laser
Sintering
 Solid Ground Curing

In this process photosensitive resin is sprayed

on the build platform. Next, the machine develops a
photomask (like a stencil) of the layer to be built. This
photomask is printed on a glass plate above the build
platform using an electrostatic process similar to that
found in photocopiers. The mask is then exposed to
UV light, which only passes through the transparent
portions of the mask to selectively harden the shape of
the current layer.

After the layer is cured, the machine vacuums

up the excess liquid resin and sprays wax in its place
to support the model during the build. The top
surface is milled flat, and then the process repeats to
build the next layer. When the part is complete, it
must be de-waxed by immersing it in a solvent bath.
UV Light Source

Spray Resin

Develop photomask

Expose mask

Vacuum uncured resin

Spray wax

Mill flat

Schematic diagram of solid ground curing

 3-D Ink-Jet Printing
Ink-Jet Printing refers to an entire class of
machines that employ ink-jet technology. Parts are
built upon a platform situated in a bin full of powder
material. An ink-jet printing head selectively deposits
or "prints" a binder fluid to fuse the powder together
in the desired areas. Unbound powder remains to
support the part. Typical layer thicknesses are on the
order of 0.1 mm. This process is very fast, and
produces parts with a slightly grainy surface.
Machines with 4 color printing capability are
available.
3D Systems' version of the ink-jet based system
is called the Thermo-Jet or Multi-Jet Printer. It uses
a linear array of print heads to rapidly produce
thermoplastic models.
 Fused Deposition Modeling
In this technique, filaments of heated
thermoplastic are extruded from a tip that moves in the
x-y plane. Like a baker decorating a cake, the controlled
extrusion head deposits very thin beads of material onto
the build platform to form the first layer. The platform is
maintained at a lower temperature, so that the
thermoplastic quickly hardens. After the platform
lowers, the extrusion head deposits a second layer upon
the first. Supports are built along the way, fastened to
the part either with a second, weaker material or with a
perforated junction.
There are variety of FDM machines ranging from
fast concept modelers to slower, high-precision
machines. Materials include ABS (standard and medical
grade), elastomer (96 durometer), polycarbonate,
polyphenolsulfone, and investment casting wax.
Schematic diagram of fused deposition modeling.
 DM features

Competitive with other RP technologies

Strong and durable model

APS plastic (with color choices) and

Elastomer material choices

Water proof, paintable

 FDM Applications
• Si3N4 components with good mechanical properties and
microstructure were produced with a filament containing 55
vol % of the ceramic. After FDM, green parts were densified
by hot pressing and gave four point bend strengths similar to
that of hot isostatic pressed parts.
• A fine scaled piezoelectric composite structure can be made
consisting of PZT AND POLYMER. The piezoelectric
properties of the composite are similar or superior to
conventionally processed PZT composites.
• Composites with controlled composition distribution and a
variety of microstructures can be made by combining
filaments of different compositions.
 Investment casting
Investment casting is a versatile process,
used to manufacture parts ranging from
turbocharger wheels to golf club heads, from
electronic boxes to hip replacement implants. The
industry, through heavily dependent on aerospace
and defence outlets, has expended to meet a
widening range of applications. Modern
investment casting ha its adoption of jet
propulsion for military and then for civilian
aircraft.
Investment casting expanded greatly
worldwide during the 1980s in particular to meet
growing demands for aircraft engine and airframe
industry, with investment castings now accounting
for 15 per cent by value of all cast metal
production in the inducers.
 Materials are used in investment casting

Investment casting is used for a wide range of

applications, small parts from the bulk of production,
but the very large components, can be be made
commercially. Nickel and cobalt base super alloys
account for 50 per cent of total output by value, steels
of all account for 35 per cent , aluminium accounts
for about 10 per cent and copper ant titanium alloys
make up a large part of the remaining 5 per cent.
 The Basic Process

Although several rapid prototyping techniques

exist, all employ the same basic five-step
process. The steps are:

• Create a CAD model of the design

• Convert the CAD model to STL format
• Slice the STL file into thin cross-sectional layers
• Construct the model one layer atop another
• Clean and finish the model
SOLID MODELS DRAWN IN
CATIA FOR RAPID
PROTOTYPING
Yoke Gear Shift
Bracket
Bracket Engine Mounting
Engine Hook
Hose Outlet
Oil Transmission Pan
JSAM1
Pump Assay Water
 Applications of Rapid Prototyping

Rapid prototyping is widely used in the

automotive, aerospace, medical, and consumer
products industries. Although the possible
applications are virtually limitless, nearly all fall
into one of the following categories: prototyping,
rapid tooling, or rapid manufacturing.

5. Prototyping
6. Rapid tooling
• Indirect tooling
• Direct tooling
• Rapid manufacturing
 Future Development
• Rapid prototyping is starting to change the way
companies design and build products.
• One such improvement is increased speed.
"Rapid" prototyping machines are still slow by
some standards. By using faster computers, more
complex control systems, and improved materials,
RP manufacturers are dramatically reducing build
time. Continued reductions in build time will
make rapid manufacturing economical for a wider
variety of products.
• Another future development is improved accuracy
and surface finish. Today’s commercially available
machines are accurate to ~0.08 millimeters in the
x-y plane, but less in the z (vertical) direction.