SEMINAR ON RAPID

PROTOTYPING
Creating Real Parts from Solid Models

Mr.G.S.SAMPATH KUMAR
JOIN WECH TECHNOLOGY
WIPRO HEALTH CARE 1
BANGALORE
 INTRODUCTION
WHAT IS A PROTOTYPE?

 A prototype is a draft version or an approximation of a final

product.

 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 conducttests
and verify performance.
 for visualization purposes.
 Some prototypes are used as market research and
promotional tools.
 Most importantly, it is cheaper to manufacture, test and
make changes to a prototype than it is to a final product.
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 RAPID PROTOTYPING
 Rapid prototyping is a broad term that comprises many different
technologies used to quickly fabricate a physical model directly from
computer data.

 The first rapid prototyping method, called stereo lithography, was

developed in the late 1980s, but more sophisticated techniques
are available today.

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 RAPID PROTOTYPING
 The terŵ ͞rapid͟ is relative. Soŵe prototypes ŵay take hours or eveŶ
days to build

 Rapid prototyping systems are additive manufacturing processes that

work on the basic principle of producing a 3D part by building and
stacking multiple 2D layers together.

 Most common types of rapid prototyping systems:

 SLA (Stereo Lithography)
 SLS (Selective Laser Sintering)
 LOM (Laminate Object Manufacturing)
 FDM (Fused Deposition Modeling).

 Different technologies use different materials to produce the parts.

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RAPID PROTOTYPING
 There are many different RP processes, but the basic operating principles
are very similar.

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BASIC OPERATING PRINCIPLES OF RP
 Building computer model

 Model is build by CAD/CAM system.

 Model must be defined as enclosed volume or solid.

 Converting model into STL file format

 Stereo Lithography (STL) file is a standard format to describe

CAD geometry used in RP system.

 STL file approximates the surfaces of the model by polygons.

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 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 10
 Includes surface finishing and other applications.
APPLICATIONS OF RP
 Applications of rapid prototyping can be classified into
three categories:

1. Design

2. Engineering analysis and planning

3. Tooling and manufacturing

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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

 Increased capability to compute mass properties

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ENGINEERING ANALYSIS AND PLANNING

 Existence of part allows certain engineering analysis and planning activities to

be accomplished that would be more difficult without the physical entity

 Comparison of different shapes and styles to determine aesthetic appeal

 Wind tunnel testing of streamline shapes

 Stress analysis of physical model

 Fabrication of pre-production parts for process planning and tool design

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 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

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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.

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 Reduces product development time considerably.
LIMITATIONS OF RP
 Some times staircase effect is observed.

 Many times component get distorted.

 Limited range of materials.

 Cost of operating.

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 STEREO LITHOGRAPHY FILES
 The stereo lithography file format, known as STL (Standard Tessellation Language), is the
current industry standard data interface for rapid prototyping and manufacturing.
 Before a 3D model is sent to a rapid prototype machine, it must be converted to this format.

 From a user standpoint, the process typically requires only exporting or saving the model as
an STL file. Some software packages, however, allow the user to define some specific
parameters.

 The STL file format defines the geometry of a model as a single mesh of triangles.
Information about color, textures, materials, and other properties of the object are ignored
in the STL file.

 When a solid model is converted into an STL file, all features are consolidated into one
geometric figure. The resulting STL file does not allow individual features created with the
parametric modeling application to be edited.

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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 that are later 19
reproduced physically by the device.
WHY .STL FILE FORMAT?
 The STL files translate the part geometry from a CAD system to the RP machine.

 Universal file format that every system needs to be able to produce so that an
RP machine can process model.

 Slicing a part is easier compared to other methods such as B-rep (boundary

representation) and CSG (constructive solid geometry)

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 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 re-solidified

 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

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 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

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 LIQUID-BASED RAPID PROTOTYPING SYSTEMS
 Starting material is a liquid Mostly resins and polymers.

 About a dozen RP technologies are in this category

 Includes the following processes:

 Stereo lithography

 Solid ground curing

 Droplet deposition manufacturing

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 SOLID-BASED RAPID PROTOTYPING SYSTEMS
 Starting material is a solid wood, plastic, metal sheets etc.

 Solid-based RP systems include the following processes:

 Laminated object manufacturing

 Fused deposition modeling

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 POWDER-BASED RP SYSTEMS
 Starting material is a powder of hard materials like

 Powder-based RP systems include the following:

 Selective laser sintering

 Three dimensional printing

 Laser engineered and Net shaping

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 STEREO LITHOGRAPHY (SLA)
 Works based on the principle of
curing liquid photomer into
specific shape
Focusing system Rotating mirror
High-speed
 A vat which can be lowered and stepper motors
raised filled with photocurable liquid
acrylate polymer He-Cd Laser

 Laser generating U-V beam is UV beam

focused in x-y directions
 The beam cures the portion of photo

Sensor system
for resin depth
polymer and produces a solid body
Liquid resin

 This process is repeated till the level Part

b is reached as shown in the figure
Support structures
 Now the plat form is lowered by
distance ab Platform

He-Ne Laser
Elevation control
 Then another portion of the
cylinder is shaped till the portion is 26
reached
 STEREO LITHOGRAPHY (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

 Accuracy(mm) - 0.01- 0.2(SLA)

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SLA: companies and applications

Shower head

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Automobile Manifold
(Rover)
STEREO LITHOGRAPHY (SLA) PARTS

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LAMINATED OBJECT MANUFACTURING (LOM)

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 LAMINATED OBJECT MANUFACTURING
 Laminated Object Manufacturing is a relatively low cost rapid prototyping technology

 where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape.

 The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform.

 When new paper is in position, it is flattened and added to the previously created
layers using a heated roller.

 The shape of the new layer is traced and cut by a blade or a laser. When the layer
is complete, the building platform descends and new paper is supplied.

 When the paper is in position, the platform moves back up so the new layer can be
glued to the existing stack, and the process repeats. 31
LAMINATED OBJECT MANUFACTURING (LOM)

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LAMINATED OBJECT MANUFACTURING FACTS
 Layer thickness(mm) - 0.1 - 1(LOM.);

 Starting sheet stock includes paper, plastic, cellulose, metals, or

fiber-reinforced materials

 Accuracy(mm) - 0.1 - 0.2(LOM);

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 FUSED DEPOSITION MODELING
• A gantry robot controlled extruder
head moves in two principle
directions over a table

• Table can be raised or lowered as

needed

• Thermo plastic or wax filament is

extruded through the small orifice
of heated die

• Initial layer placed on a foam

foundation with a constant rate

• Extruder head follows a

predetermined path from the file

• After first layer the table is

lowered and subsequent layers are Fig : (a)Fused-deposition-modeling
formed process3.5 (b)The FDM 5000, a fused-
decomposition- modeling-machine.
FDM: companies and applications
FDM™ is a patented technology of Stratasys™ Inc.

Gear assembly
Toy design using FDM models of different colors

Monkey Cinquefoil 36
Designed by Prof Carlo Sequin, UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
FUSED DEPOSITION MODELING (FDM)

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 FUSED DEPOSITION MODELING (FDM)
 Materials:
ABS,
Polycarbonate (PC),
Polyphenylsulfonen (PPSF) Metals

 Layer thickness(mm) - ~0.05(FDM);

 Accuracy(mm) - 0.127 -
0.254(FDM);

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 SELECTIVE LASER SINTERING (SLS)
 Uses a high power laser and powdered materials.

 A wide variety of materials can be used, ranging from thermoplastic

polymers, such as nylon and polystyrene, to some metals.

 3D parts are produced by fusing a thin slice of the powdered material

onto the layers below it.

 The surfaces of SLS prototypes are not as smooth as those produced

by SLA processes.

 SLS parts are sufficiently strong and resistant for many functional
tests.

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SELECTIVE LASER SINTERING (SLS)

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 SELECTIVE LASER SINTERING (SLS)
 The powdered material is kept on a delivery platform and supplied to the
building area by a roller.

 For each layer, a laser traces the corresponding shape of the part on the
surface of the building area, by heating the powder until it melts, fusing it with
the layer below it.

 The platform containing the part lowers one layer thickness and the platform
supplying the material elevates, providing more material to the system.

 The roller moves the new material to the building platform, leveling the surface,
and the process repeats.

 Some SLS prototype machines use two delivery platforms, one on each side of
the building platform, for efficiency, so the roller can supply material to the
building platform in both directions.
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 3D printing
Technology invented at MIT in1994, Part constructed with starch
powder
1.Layer of powder spread on platform
2.Ink-jet printer head deposits drops of water/glue* on part cross-
section
3.Table lowered by layer thickness
4.New layer of powder deposited above previous layer
5.Repeat steps 2-4 till part is built
6.Shake powder to get part

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MATERIALS USED:
STARCH, PLASTER-CERAMIC POWDER, METAL POWDER
MULTI-COLORED WATER CAN BE USED TO MAKE ARBITRARY COLORED PARTS
(SAME AS INK-JET PRINTING)

 Applications of 3DP
 CAD-Casting metal parts. A ceramic shell with integral cores can
be
fabricated directly from the CAD model
 Direct metal parts. It is adaptable to a variety of material systems,
allowing the production of metallic/ceramic parts with novel
composition
 Prototypes with colours and elastic feature

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