RTC Institute of Technology ANANDI, RANCHI-834 003

RTC INSTITUTE OF TECHNOLOGY
ANANDI , RANCHI- 834 003
UNDER GUIDANCE OF
1. Dr. Israr Equbal
Department of Manufacturing Engg., NIFFT, HATIA
SUBMITTED BY
Abhishek Raj
B. Tech(Vth sem)
Mechanical Engg.
(2009-13)
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.
All RP techniques employ the basic fivestep process.

1.
Create a CAD model of the design
2.
Convert the CAD model to STL format

(stereolithography)
3.
Slice the STL file into thin cross-sectional layers
4.
Construct the model one layer atop another
5.
Clean and finish the model
CAD Model Creation:

First, the object to be built is modeled using a
Computer-Aided Design (CAD) software package.
Solid modelers, such as Pro/ENGINEER, tend to
represent 3-D objects more accurately than wireframe modelers such as AutoCAD, and will
therefore yield better results.
This process is identical for all of the RP build
techniques.
Conversion to STL Format:

To establish consistency, the STL (stereolithography,
the first RP technique) format has been adopted as
the standard of the rapid prototyping industry.
The second step, therefore, is to convert the CAD file
into STL format. This format represents a threedimensional surface as an assembly of planar
triangles
STL files use planar elements, they cannot represent
curved surfaces exactly. Increasing the number of
triangles improves the approximation
Slice the STL File:

In the third step, a pre-processing program
prepares the STL file to be built.
The pre-processing software slices the STL model
into a number of layers from 0.01 mm to 0.7 mm
thick, depending on the build technique.
The program may also generate an auxiliary
structure to support the model during the build.
Supports are useful for delicate features such as
overhangs, internal cavities, and thin-walled
sections.
Layer by Layer Construction:

The fourth step is the actual construction of the part.
RP machines build one layer at a time from polymers,
paper, or powdered metal.
Most machines are fairly autonomous, needing little
human intervention.
Clean and Finish:
The final step is post-processing. This involves

removing the prototype from the machine and
detaching any supports.
Some photosensitive materials need to be fully
cured before use
Prototypes may also require minor cleaning and
surface treatment.
Sanding, sealing, and/or painting the model will
improve its appearance and durability.
SLS --- Selective Laser Sintering
SLA --- Stereolithography
LOM --- Laminated Object Manufacturing
FDM --- Fused Deposition Modeling
Others
Selective Laser Sintering
Application Range
Visual Representation models
Functional and tough prototypes
cast metal parts
Advantages
Flexibility of materials used

PVC, Nylon, Sand for building sand casting cores,
metal and investment casting wax.
No need to create a structure to support the part
Parts do not require any post curing except when
ceramic is used.
Disadvantages
During solidification, additional powder may be

hardened at the border line.
The roughness is most visible when parts contain
sloping (stepped) surfaces.
The Stereolithography Machine
PT CAM uses a
stereolithography machine
produced by 3-D Systems and
shown here:
Stereolithography
Patented in 1986, stereolithography started

the
rapid
prototyping
revolution.
The
technique builds three-dimensional models
from liquid photosensitive polymers that
solidify when exposed to ultraviolet light.
(FDM) is a solid-based rapid prototyping method that

extrudes material, layer-by-layer, to build a model.
A thread of plastic 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.
Easy
fabrication
Minimal wastage
Ease of removal
Easy handling
Designing
Engineering
analysis and
planning
Tooling and manufacturing
FDM 2000 Specifications
Prodigy Specifications
Build Volume: 10" x 10" x 10"

Materials:ABS, Casting Wax
Build Step Size: 0.005" to
0.030"
Build Volume: 8" x 8" x 10"

Materials: ABS, Casting Wax
Build Step Size: 0.007", 0.010",
0.013"
Up to 4x faster than the FDM 2000
As the name implies the process laminates

thin sheets of film (paper or plastic)
The laser has only to cut/scan the periphery

of each layer
The process:
The build material (paper with a thermo-setting

resin glue on its under side) is stretched from a
supply roller across an anvil or platform to a takeup roller on the other side.
A heated roller passes over the paper bonding it to
the platform or previous layer.
A laser, focused to penetrate through one
thickness of paper cuts the profile of that layer.
The excess paper around and inside the model is
etched into small squares to facilitate its removal.
The process continued:

The process of gluing and cutting continuous
layer by layer until the model is complete.
To reduce the build time, double or even triple
layers are cut at one time which increases the
size of the steps on curved surfaces and the
post processing necessary to smooth those
surfaces.
Wide
range of materials
Fast
Build time
High
accuracy
Applications of LOM objects:

LOM objects are durable, multilayered structures
which can be machined, sanded, polished, coated
and painted.
Used as precise patterns for secondary tooling
processes such as rubber moulding, sand casting
and direct investment casting.
Medical sector for making instruments.
Rapid prototyping Processes

Other Processes
3D Printing
Model Maker
Ballistic Particle Manufacturing
Thank
you

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RTC INSTITUTE OF TECHNOLOGY

ANANDI , RANCHI- 834 003

prototyping technologies are able to produce physical

is capable to fabricate parts quickly with too complex

helps in earlier detection and reduction of design errors.

All RP techniques employ the basic fivestep process.

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

CAD Model Creation:

Conversion to STL Format:

Slice the STL File:

Layer by Layer Construction:

Clean and Finish:

The final step is post-processing. This involves

SLS --- Selective Laser Sintering

SLA --- Stereolithography

LOM --- Laminated Object Manufacturing

FDM --- Fused Deposition Modeling

Selective Laser Sintering

Flexibility of materials used

During solidification, additional powder may be

The Stereolithography Machine

Patented in 1986, stereolithography started

(FDM) is a solid-based rapid prototyping method that

A thread of plastic is fed into an extrusion head, where

Support material is also laid down in a similar manner.

FDM 2000 Specifications

Build Volume: 10" x 10" x 10"

Build Volume: 8" x 8" x 10"

As the name implies the process laminates

The laser has only to cut/scan the periphery

The build material (paper with a thermo-setting

The process continued:

Applications of LOM objects:

Rapid prototyping Processes

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