Chapter 9

Chapter 9
Rapid Prototyping
 Rapid prototyping (RP) is a family of fabrication methods to make
engineering prototypes in minimum possible lead times based on a
computer-aided design (CAD) model of the item.
 The creation of a prototype is an integral step in the design
procedure.
 The common approach to prepare the control instructions (part
program) in all of the current material addition RP techniques
involves the following steps
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Conti…
Geometric modeling
Tessellation of the geometric model
Slicing of the model into layers
The classification method is based on the form of
the starting material in the RP process:
(1) liquid-based, (2) solid-based, and (3) powder-
based.
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Liquid-based Rapid Prototyping Systems
The starting material in these technologies is a

liquid. About a dozen RP technologies are in this
category, of which we have selected the following
to describe:
1)Stereo lithography,
2)solid ground curing, and
3)droplet deposition manufacturing
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Conti…
 Stereo lithography (STL) is a process for fabricating a
solid plastic part out of a photosensitive liquid polymer
using a directed laser beam to solidify the polymer.
 The stereo lithography apparatus consists of
(1) a platform that can be moved vertically inside a vessel
containing the photosensitive polymer, and
(2) a laser whose beam can be controlled in the x-y
direction.
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Stereo lithography:
(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.
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Fused-Deposition Modeling
 Fused-deposition modeling (FDM) is an RP process in
which a filament of wax or polymer is extruded onto the
existing part surface from a work head to complete each
new layer.
 The work head is controlled in the x-y plane during each
layer and then moves up by a distance equal to one layer
in the z-direction.
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Laser Sintering
 Selective laser sintering (SLS) uses a moving laser beam to
sinter heat-fusible powders in areas corresponding to the CAD
geometric model one layer at a time to build the solid part.
After each layer is completed, a new layer of loose powders is
spread across the surface using a counter-rotating roller.
 The powders are preheated to just below their melting point to
facilitate bonding and reduce distortion.
 Layer by layer, the powders are gradually bonded into a solid
mass that forms the three-dimensional part geometry.
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Applications And Limitations RP
Applications of rapid prototyping can be classified into
three categories:
1) Design
2) engineering analysis and planning, and
3) tooling and manufacturing.
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Design
 This was the initial application area for RP
systems. Designers are able to confirm their design
by building a real physical model in minimum time
using rapid prototyping.
 The features and functions of the part can be
communicated to others more easily using a
physical model than by a paper drawing or
displaying it on a CAD system monitor. Benefits to
9 design attributed to rapid prototyping include
Conti…
(1)Reduced lead times to produce prototype
components,
(2)Improved ability to visualize the part geometry
because of its physical existence,
(3)earlier detection and reduction of design errors, and
(4)increased capability to compute mass properties of
components and assemblies.
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Engineering Analysis and Planning
(1)comparison of different shapes and styles to optimize
aesthetic appeal of the part;
(2)analysis of fluid flow through different orifice designs
in valves fabricated by RP;
(3)wind tunnel testing of different streamline shapes using
physical models created by RP;
(4) stress analysis of a physical model and
(5)fabrication of preproduction parts by RP as an aid in
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process planning and tool design
Tooling and Manufacturing
 The trend in RP applications is toward its greater use in
the fabrication of production tooling and for actual
manufacture of parts.
 When RP is adopted to fabricate production tooling, the
term rapid tool making (RTM) is often used. RTM
applications divide into two approaches : indirect RTM
method, in which a pattern is created by RP and the
pattern is used to fabricate the tool, and direct RTM
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method, in which RP is used to make the tool itself .
Problems with Rapid Prototyping.
The principal problems with current RP technologies
1. part accuracy,
2. limited variety of materials, and
3. mechanical performance of the fabricated parts.
Several sources of error limit part accuracy in RP
systems:
(1) mathematical,
(2) process related,
(3)
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material related
Rapid tooling
 Rapid tooling (RT) and rapid prototyping (RP) is any
method or technology that enables one to produce a
tool or product quickly.
 The term rapid tooling refers to RT-driven tooling.
 A prototype is a 3-D model suitable for use in the
preliminary testing and evaluation of a mold, die or
product.
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Techniques Of Rapid Manufacturing
 Rapid manufacturing relies on a variety of tools and
processes to create products.
 These include additive manufacturing, subtractive tools
like CNC machining, and rapid tooling for traditional
manufacturing methods.
 As rapid prototypes are usually constructed
using additive fabrication techniques.
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