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Introduction To Rapid Prototyping

This document provides an overview of rapid prototyping (RP). It discusses two categories of RP: material removal and material addition. Material addition RP works by adding layers of material one at a time to build a solid part from bottom to top. The main material addition techniques are those using liquid monomers, powders, or solid sheets as the starting material. Key RP methods covered include stereolithography, fused deposition modeling, selective laser sintering, and three dimensional printing. The document also discusses the benefits of RP for product designers and its use in both prototyping and manufacturing applications.

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156 views19 pages

Introduction To Rapid Prototyping

This document provides an overview of rapid prototyping (RP). It discusses two categories of RP: material removal and material addition. Material addition RP works by adding layers of material one at a time to build a solid part from bottom to top. The main material addition techniques are those using liquid monomers, powders, or solid sheets as the starting material. Key RP methods covered include stereolithography, fused deposition modeling, selective laser sintering, and three dimensional printing. The document also discusses the benefits of RP for product designers and its use in both prototyping and manufacturing applications.

Uploaded by

familyuma
Copyright
© Attribution Non-Commercial (BY-NC)
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPT, PDF, TXT or read online on Scribd
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RAPID PROTOTYPING

1. Fundamentals of Rapid Prototyping 2. Rapid Prototyping Technologies 3. Applications and Benefits of Rapid Prototyping

Rapid Prototyping (RP)


A family of fabrication processes developed to make engineering prototypes in minimum lead time based on a CAD model of the item Traditional method is machining Can require significant lead-times several weeks, depending on part complexity and difficulty in ordering materials RP allows a part to be made in hours or days, given that a computer model of the part has been generated on a CAD system

Why is Rapid Prototyping Important?


Product designers want to have a physical model of a new part or product design rather than just a computer model or line drawing A virtual prototype (a CAD model of the part) may not be sufficient for the designer to visualize the part adequately Using RP to make the prototype, the designer can see and feel the part and assess its merits and shortcomings

RP Two Basic Categories:


1. Material removal RP - machining, using a dedicated CNC machine that is available to the design department on short notice Starting material is often wax Easy to machine Can be melted and resolidified The CNC machines are often small - called desktop machining 2. Material addition RP - adds layers of material one at a time to build the solid part from bottom to top

Starting Materials in Material Addition RP


1. Liquid monomers that are cured layer by layer into solid polymers 2. Powders that are aggregated and bonded layer by layer 3. Solid sheets that are laminated to create the solid part

Addition RP Methods
In addition to starting material, the various material addition RP technologies use different methods of building and adding layers to create the solid part There is a correlation between starting material and part building techniques

Steps to Prepare Control Instructions


1. Geometric modeling - model the component on a CAD system to define its enclosed volume 2. The CAD model is converted into a computerized format that approximates its surfaces by facets (triangles or polygons)

3. Slicing of the model into layers - computerized model is sliced into closely-spaced parallel horizontal layers

Solid Model to Layers

Figure 34.1 Conversion of a solid model of an object into layers (only one layer is shown).

More About Rapid Prototyping


Alternative names for RP: Layer manufacturing Direct CAD manufacturing Solid freeform fabrication

Rapid prototyping and manufacturing (RPM)


RP technologies are being used increasingly to make production parts and production tooling, not just prototypes

Classification of RP Technologies
There are various ways to classify the RP techniques that have currently been developed The RP classification used here is based on the form of the starting material:

1. Liquid-based
2. Solid-based 3. Powder-based

Liquid-Based Rapid Prototyping Systems


Starting material is a liquid About a dozen RP technologies are in this category Includes the following processes: Stereolithography Solid ground curing Droplet deposition manufacturing

Stereolithography

Figure 34.2 Stereolithography: (1) at the start of the process, in which the initial layer is added to the platform; and (2) after several layers have been added so that the part geometry gradually takes form.

Solid Ground Curing


Figure 34.4 SGC steps for each layer: (1) mask preparation, (2) applying liquid photopolymer layer,(3) mask positioning and exposure of layer, (4) uncured polymer removed from surface, (5) wax filling, (6) milling for flatness and thickness.

Solid-Based Rapid Prototyping Systems


Starting material is a solid Solid-based RP systems include the following processes: Laminated object manufacturing Fused deposition modeling

Laminated Object Manufacturing

Figure 34.5 Laminated object manufacturing.

Fused deposition modeling

Powder-Based RP Systems
Starting material is a powder Powder-based RP systems include the following: Selective laser sintering Three dimensional printing

Selective laser sintering

Three Dimensional Printing

Figure 34.6 Three dimensional printing: (1) powder layer is deposited, (2) ink-jet printing of areas that will become the part, and (3) piston is lowered for next layer (key: v = motion).

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