RAPID PROTOTYPING

V KALYANAMANOHAR

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 •Manufacturing

Additive Subtractive
Fabrication processes
 Subtractive process- single block of solid material larger than the final size of
the desired object.
Ex: CNC with turning, milling, drilling, Laser cutting, WJC..etc
 additive process -reverse – end product is much larger than the material. Ex:
SLA, SLS
 Formative - mechanical forces.
Ex: bending, forging, plastic injection molding.
 Prototype fundamentals
Definition : A prototype is the first or original example of
something that has been or will be copied or developed; it is a
model or preliminary version.
e.g.: A prototype supersonic aircraft
Prototypes are developed for several reasons:
✓to identify possible problems.
✓to confirm the suitability of a design prior to starting mass
production.
✓Provides a scale model to conduct tests and verify
performance.
✓for visualization purposes.
•Layer Manufacturing -Material Addition Manufacturing
•Material Deposit Manufacturing -Material Ingress Manufacturing
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•Desktop Manufacturing -CAD Oriented Manufacturing
 INTRODUCTION
➢ Rapid prototyping technologies are able to produce physical
model in a layer by layer manner directly from their CAD
models without any tools, dies and fixtures and also with
little human intervention.
➢ RP is capable to fabricate parts quickly with too complex
shape easily as compared to traditional manufacturing
technology.
➢ RP helps in earlier detection and reduction of design errors.
HISTORICAL DEVELOPMENT
Year of Inception Technology
1770 Mechanization
1946 First Computer
1952 First Numerical Control (NC) Machine Tool
1960 First commercial Laser
1961 First commercial Robot
1963 First Interactive Graphics System(early version of Computer-Aided Design)
1988 First commercial Rapid Prototyping System

The third revolution “is under

way” and that consists of manufacturing
“going digital.”

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Design Applications
 Designers are able to confirm their design by building a real physical
model in minimum time using RP
 Design benefits of RP:

 Reduced lead times to produce prototypes

 Improved ability to visualize part geometry
 Early detection of design errors

ENGINEERING ANALYSIS AND PLANNING

 Comparison of different shapes and styles to determine aesthetic
appeal
 Stress analysis of physical model
 Fabrication of pre-production parts for process planning and tool
design
 TOOLING APPLICATIONS
 Called rapid tool making (RTM) when RP is used to fabricate
production tooling
 Two approaches for tool-making:
1)Indirect RTM method
•Pattern is created by RP and the pattern is used to fabricate the
tool
 Examples:
 Patterns for sand casting and investment casting
 Electrodes for EDM
2 )Direct RTM method
•RP is used to make the tool itself
 Example:
 3DP to create a die of metal powders followed by sintering and
infiltration to complete the die.
ADVANTAGES OF RAPID PROTOTYPING
 Process is Fast and accurate.
 Superior Quality surface finish is obtained.

 Separate material can be used for component and support .

 No need to design jigs and fixtures.

 No need of mould or other tools.

 Post processing include only finishing and cleaning.

 Harder materials can be easily used .

 Minimum material wastage.

LIMITATIONS OF RP
 Many times component get distorted.
 Limited range of materials.
 Cost of operating. •1
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Methodology
 Building computer model
 Model is building by CAD/CAM system
 Model must be defined as enclosed volume or solid.
 Converting model into STL file format
 STereoLithography (STL) file is a standard format to describe CAD geometry
used in RP system
 STL file approximates the surfaces of the model by polygons.
 Fabricating the model
 Building model layer by layer
 Forming a 3D model by solidification of liquid/powder
 Removing support structure and cleaning
 After building Drain out extra material.
 Cut out the prototype.
 Cut out unnecessary support material.
Post processing
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INVENTOR .STL SAVE PROCEDURE
•Remember to
use “Save Copy
As” not “Save.”

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•Select .stl as file type
STEREO LITHOGRAPHY FILES
 The process of approximating the actual surfaces of the object with a
•closed mesh of triangles is known as Tessellation.

 When the tessellated STL file is sent to the rapid prototype

machine, the model is sliced into multiple horizontal layers •1
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that are later reproduced physically by the device.
 •3D MODELING
Advanced 3D CAD modeling is a general prerequisite in RP processes and
usually is the most time-consuming part of the entire process chain.
•DATA CONVERSION AND TRANSMISSION
•The solid or surface model to be built is next converted into a format
dubbed the STL file format.

•The STL file format approximates the surfaces of the model using tiny
triangles.
CHECKING AND PREPARING
•At present, the CAD model errors are corrected by human operators assisted
by specialized software such as MAGICS.

•Once the STL files are verified to be error-free, the RP system’s computer
analyzes the STL files that define the model to be fabricated and slices the
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model into cross-sections.
 •BUILDING
•For most RP systems, this step is fully automated. Thus, it is usual
for operators to leave the machine on to build a part overnight. The
building process may take up to several hours to build depending on
the size and number of parts required.

• Removing support structure and cleaning

• After building Drain out extra material.
• Cut out the prototype.
• Cut out unnecessary support material.
•POSTPROCESSING
•The final task in the process chain is the postprocessing task. At this
stage, generally some manual operations are necessary. As a result,
the danger of damaging a part is particularly high.
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Classification of RP Systems
 Classification of RP Systems
Liquid-based
(1) 3D Systems’ Stereolithography Apparatus (SLA)
(2) Cubital’s Solid Ground Curing (SGC)
(3) Sony’s Solid Creation System (SCS)
(4) CMET’s Solid Object Ultraviolet-Laser Printer (SOUP)
 Solid-based: Encompass all forms of material in the solid form, such as wire, a roll,
laminates and pellets.
(1) Cubic Technologies’ Laminated Object Manufacturing (LOM)
(2) Stratasys’ Fused Deposition Modeling (FDM)
(3) Kira Corporation’s Paper Lamination Technology (PLT)
(4) 3D Systems’ Multi-Jet Modeling System (MJM)
Powder-based: Grain-like material  Joining/Binding  Solid
(1) 3D Systems’s Selective Laser Sintering (SLS)
(2) Z Corporation’s Three-Dimensional Printing (3DP)
•17 (3) Optomec’s Laser Engineered Net Shaping (LENS)
(4) Soligen’s Direct Shell Production Casting (DSPC)
Stereolithography Apparatus (SLA)
 SLA was developed in 1986 by 3D Systems. The process is based on the
following principle:
 Parts are built from a photo-curable liquid resin that solidifies when sufficiently
exposed to a laser beam which scans across the surface of the resin
 The building is done layer by layer, each layer being scanned by the optical
scanning system and controlled by an elevation mechanism which lowers at the
completion of each layer.

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 Process of SLA
Step 1 -A liquid state photosensitive polymer that solidifies when
exposed to a lighting source
Step 2 -A platform that can be elevated is located just one layer of
thickness below the surface
Step 3 -According to the cross section of the part (starting with
bottom layer). The laser scans the polymer layer above the platform
to solidify the polymer.
Step 4 -The Platform is lowered into the polymer bath to the layer
thickness
Step 5 -Repeat 3 and 4 until the top layer of the part is generated
Step 6 -Post-curing and part finishing will then be performed

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•PHOTOPOLYMERIZATION
•There are many types of liquid photopolymers that can be solidified
by exposure to electro-magnetic radiation, including wavelengths in
the gamma rays, X-rays, UV and visible range, or electron-beam (EB)
systems, including 3D Systems’ SLA machines are curable in the UV
range.
• UV-curable photopolymers are resins which are formulated from
photo initiators and reactive liquid monomers.
•The process through which photopolymers are cured is referred to as
the photopolymerization process.
•Polymerization is the process of linking small molecules (known as
monomers) into chain-like larger molecules (known as polymers).
When the chain-like polymers are linked further to one another, a
cross-linked polymer is said to be formed.

•Photopolymerization is polymerization initiated by a photochemical

process whereby the starting point is usually the induction of energy
from the radiation source
Schematic for a simplified free-radical photopolymerization
 Advantages
 Round the clock operation:
The SLA can be used continuously and unattended round the clock.
 Good user support:
The computerized process serves as a good user support.
 Build volumes:
The different SLA machines have build volumes ranging from small to large to suit the
needs of different users.
 Good accuracy:
The SLA has good accuracy and can thus be used for many application areas.
 Surface finish:
The SLA can obtain one of the best surface finishes amongst RP technologies.
 Wide range of materials:
There is a wide range of materials, from general-purpose materials to specialty
materials for specific applications.
 Disadvantages
 Requires support structures:
Structures that have overhangs and undercuts must have supports that are
designed and fabricated together with the main structure.
 Requires post-processing:
Post-processing includes removal of supports and other unwanted materials,
which is tedious, time-consuming and can damage the model.
 Requires post-curing:
Post-curing may be needed to cure the object completely and ensure the
integrity of the structure.
Applications of SLA
 Prototypes for design, analysis, verification and functional testing
 Masters for prototype tooling and low volume production tooling
 Patterns for investment casting, sand casting and moulding
 Tools for fixture and tooling design and production tooling
SLA: companies and applications
•Companies that develop and sell SLA machines:
1. 3D Systems Inc. (www.3Dsystems.com)
2. Aaroflex Inc (www.aaroflex.com)

•Shower head

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•Automobile Manifold
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•(Rover)
 Facts about SLA
•Each layer is 0.076 mm to 0.50 mm (0.003 in to 0.020 in.) thick
•Thinner layers provide better resolution and more intricate
shapes; but processing time is longer
•Starting materials are liquid monomers
•Polymerization occurs on exposure to UV light produced by laser
scanning beam
•Scanning speeds ~ 500 to 2500 mm/s
•Cost of materials: the resin costs as much as $600-$800 per
gallon. (For a 20”x20”x23” cube that’s 39.8 gallons! …$27,860)

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 Principle of Selective Laser Sintering (SLS)
SLS was developed by DTM Corporation in 1992. The process is based on the
following principle:
 Parts are built by sintering when a CO2 laser beam hit a thin layer a powdered
material. The interaction of the laser beam with the powder raises the temperature,
resulting in particle melting and bonding together.
 The building of the part is done layer by layer. The next layer built directly on the
top of the sintered layer after an additional layer of powder is deposited via a roller
mechanism on the top of the previously formed layer.

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•Process
Step 1 - A part cylinder is located at the height necessary for a
layer of powdered material to be deposited on the cylinder to the
desired thickness. The powder is applied from the feed cylinder by the
levelling roller.
Step 2 - The layer of powder is selectively raster- scanned and
heated with a laser, causing particles to adhere to each other. The
laser scan forms the powder into the required cross section shape.
Again this step starts with the bottom cross section
Step 3 - The part cylinder is lowered by the layer thickness to
permit a new layer of powder to be deposited
Step 4 - The new layer is scanned, conforming it to the shape of the
next upper cross-section and adhering it to the previous layer.
Step 5 - Repeat 3 and 4 until the top layer of the part is generated
Step 6 - Post-curing may be required for some material.
 •Advantages •Disadvantages
(1)Good part stability. (1)Large physical size of the unit
(2) Wide range of processing materials. (2)High power consumption
(3)No part supports required (3)Poor surface finish
(4)Little post-processing required
(5)No post-curing required
•Materials
• In theory, a wide range of thermoplastics, composites, metals and ceramics
can be used in this process, thus providing an extensive range of functional
parts to be built.
• Polyamide
• Thermoplastic elastomer
• Polycarbonate
• Nylon Metal
• Ceramics.
 Example of SLS Part

•Metal mold using SLS, injection molded parts Prototypes for Reebok golf shoe
soles produced by SLS
 Fused Deposition Modeling
 Stratasys Inc. was founded in 1989 and has developed most of the company’s
products based on the Fused Deposition Modeling (FDM) technology.
 The technology was first developed by Scott Cramp in 1988 and the patent was
awarded in the U.S. in 1992.
 (FDM) is a solid-based rapid prototyping method that extrudes material, layer-
by-layer, to build a model.
 A thread of thermoplastic is fed into an extrusion head, where it is heated into a
semi-liquid state and extruded through a very small hole onto the previous layer
of material.
 Support material is also laid down in a similar manner.
Working
fdm-small.png
•Process of FDM
The process of FDM is relatively simple and fast but its use is limited to thermoplastic materials

Step 1 - A geometric model of a conceptual design is created on a CAD software which uses IGES
or STL formatted files.

Step 2 - It can then imported into the workstation where it is processed through the QuickSlice
and Support Work propriety software before loading to FDM 3000 or similar systems.

Step 3 - The slice thickness can be set manually to anywhere between 0.005” to 0.014 “
depending on the needs of the models.

Step 4 - The thermoplastic material in the form of filament is heated to just above its
solidification temperature

Step 5 - The extrusion head is heated and moves according to the pattern of the cross section of
each layer of the part

Step 6 - The material is extruded on the foundation or previously built layer. As it is extruded, it is
cooled and thus solidifies to form the required pattern of part

Step 7 - Repeat 5 and 6 until the top layer of the part is generated

Step 8 - Part finishing may be required

 Advantages
 Fabrication of functional parts:
fabricate prototypes with materials that are similar to that of the actual molded product.
Acrylonitrile Butadiene Styrene – 85%
 Minimal wastage:
build parts directly by extruding semi-liquid melt onto the model. material needed to
build the part and its support are needed-material wastages are kept to a minimum.-little
need for cleaning up the model after it has been built.
 Ease of support removal:
With the use of Break Away Support System (BASS) and Water Works Soluble Support
System, support structures generated during the FDM building process can be easily
broken off or simply washed away-makes it very convenient for users to get to their
prototypes very quickly and there is very little or no post-processing necessary.
 Ease of material change:
Build materials, supplied in spool form (or) cartridge form in the case of the Dimension or
Prodigy Plus), are easy to handle and can be changed readily when the materials RP-in the
system are running low-keeps the operation of the machine simple and the maintenance
relatively easy.
 Disadvantages
 Restricted accuracy: Parts built with the FDM process usually have restricted
accuracy due to the shape of the material used, i.e., the filament form- 1.27 mm.
 Slow process:
The building process is slow, as the whole cross-sectional area needs to be filled
with building materials. Building speed is restricted by the flow rate of the build
material from the extrusion head. As the build material used are plastics and their
viscosities are relatively high, the build process cannot be easily speeded up.
 Unpredictable shrinkage:
As the FDM process extrudes the build material from its extrusion head and
cools them rapidly on deposition, stresses induced by such rapid cooling
invariably are introduced into the model. As such, shrinkages and distortions
caused to the model built are a common occurrence and are usually difficult to
predict, though with experience, users may be able to compensate for these by
adjusting the process parameters of the machine.
 FDM Applications

•Gear assembly
•Toy design using FDM models of different colors FDM material
•Some more applications….
 Thank You

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 Advantages
1.Solid Ground curing framework do not need a help structure. No extra
support is needed since wax is utilized to fill the voids.
2.Accuracy of procedure. The model created by Solid Ground Curing
process is nearly precise in the Z-bearing in light of the fact that the layer is
processed after each light-presentation process.

Limitations

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 3D Printing

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 APPLICATIONS
•Advanced Manufacturing
 Airbus would like to make a 3D printer that is large enough to make
planes from the ground up – a hangar-size printer as large as 80m x 80m.
 Made In Space is a US company experimenting with zero-gravity 3D
printing. The process could potentially allow astronauts to print objects
as required in space, saving valuable weight at launch.
 NASA has been looking at 3D printing for some time now, and
considering the technology for long missions where astronauts could
create their own equipment during the trip.
 Custom hearing aids and braces.
 Body parts, including ears, hips and even organs, in exact proportions to
fit the patient.
 In February 2012, surgeons successfully implanted an entire titanium
jaw, made with 3D printing, in an elderly woman.
 Medical Procedures

3D Printing can make parts in Biocompatible materials

Accessories
•Geometric complexity is not a limitation in 3D Printing
•Applications of 3D Printing

•Touch and Feel

•Applications of 3D Printing

•Form, Fit and Function

 •Applications of 3D Printing

•Courtesy: brandonsmarathon.com
•Applications of 3D Printing

•Molds for Casting

 •Applications of 3D Printing
01 011 021 031

041 051 061 071

081 091 092 10

•Jewelry Design
•Applications of 3D Printing

•Direct Tooling
•Medical Implants by 3D Printing
•Applications of 3D Printing

•Prototypes for Medical Applications

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