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BMM3643
Manufacturing Process

Lecturer: Dr. Siti Rabiatull Aisha Idris

Email: rabiatull@ump.edu.my
Phone: 09-4246349

7.0 FORMING AND SHAPING FOR

PLASTICS AND COMPOSITES: Rapid
Prototyping

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Lesson Objectives:
After todays lecture, students should be able to:
Analyze the process of rapid prototyping
operation

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Rapid-Prototyping Operations

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Introduction
Rapid prototyping is the automatic construction of physical
objects using solid freeform fabrication.
Solid freeform fabrication (SFF) is a technique for
manufacturing solid objects by the sequential delivery of
energy and/or material to specified points in space to produce
that solid.
SFF is sometimes referred to as rapid prototyping, rapid
manufacturing, layered manufacturing and additive
fabrication.
Used mostly in the development stage of a new product or
low production quantity

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Introduction (cont.)
RP takes virtual designs from CAD or animation modeling
software, transforms them into thin horizontal cross sections,
still virtual, and then creates each cross section in physical
space, one after the next until the model is finished.
The machine reads in data from a CAD drawing and lays down
successive layers of liquid, powder, or sheet material, and in
this way builds up the model from a series of cross sections.
These layers, which correspond to the virtual cross section
from the CAD model, are joined together or fused
automatically to create the final shape.

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1.0 Rapid-Prototyping

1.0 Rapid-Prototyping
Classification of Rapid Prototyping
i.

Subtractive ( Removal of material )

ii. Additive ( Adding of material )
iii. Virtual ( Advanced computer base visualization)

Almost materials can be manufactured through a

rapid-prototyping operation, but polymers are the
work piece material most commonly used today.

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Parts Made by Rapid-Prototyping

(c)
(a)

(b)

Examples of parts made by rapid-prototyping processes: (a) selection

of parts from fused-deposition modeling; (b) stereolithography model of
cellular phone; and (c) selection of parts from three-dimensional printing.
Source: Courtesy of Stratasys, Inc., (b) and (c) Courtesy of 3D Systems,
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Inc.

i. Subtractive Process
Subtractive process use computer based prototype
technology to speed the process
Essential technologies for subtractive prototyping :
i.
ii.
iii.
iv.

Computer based drafting packages ( 3-D representation of

parts)
Interpretation software (Translation of cad file to
manufacturing software)
Manufacturing Software (Planning Machining operations)
Computer-Numerical Control Machinery

For shape verification, polymer or wax is used

For actual application, a machining process still required
Production time varies from few days to weeks
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ii. Additive Process

Build parts in layer by layer (slice by slice as stacking a
loaf of bread) & require elaborate software
Steps;
1. Obtain CAD file
2. Computer then constructs slices of a 3-dimensional part
3. Slice analyzed and compiled to provide the rapid
prototyping machine
4. Setup of the proper unattended and provide rough part
after few hours
5. Finishing operations and sanding and painting

Production time varies from few minutes to hours

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Characteristics of Additive RapidPrototyping Technologies

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ii. Additive Process - Liquid supply

a. Stereolithography
Works based on the principle of curing liquid
photomer into specific shape
A vat which can be lowered and raised filled with
photocurable liquid polymer
Laser generating U-V beam is focused in x-y directions
The beam cures the portion of photo polymer and
produces a solid body
This process is repeated till the level b and c is reached
as shown in the figure below

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Schematic illustration of the stereolithography process.

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Computational Steps in
Rapid Prototyping
The computational steps in
producing a stereolithography file.
(a) Three-dimensional description of
each part.
(b) The part is divided into slices
(only one in 10 is shown).
(c) Support material is planned.
(d) A set of tool directions is
determined to manufacture each
slice. Also shown is the extruder
path at section A-A from (c) for a
fused-deposition-modeling
operation.

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ii. Additive Process - Liquid supply

b. Fused Deposition Modeling
FDM extrudes hot plastic or wax through a nozzle,
building up a model.
A gantry robot controlled extruder head moves in
two principle directions over a table
Table can be raised or lowered as needed
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 formed
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(a) Schematic illustration of the fused-deposition-modeling process. (b) The FDM 5000, a fused-depositionmodeling machine.
Source: Courtesy of Stratysis, Inc.
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ii. Additive Process - Powder

c. Selective Laser Sintering (SLS)
Selective laser sintering uses a laser to fuse powdered nylon, elastomer,
or metal. Additional processing is necessary to produce fully dense
metal part.
Basic elements in this process are bottom of chambers equipped with 2
cylinders.
Powder feed cylinder which is raised incrementally to supply powder to
part-build cylinder through a roller mechanism
Part-build cylinder which is lowered incrementally to where the sintered
part is formed.
Layer of powder is first deposited on part build cylinders
A laser beam controlled by instruction from 3-D file is focused on that
layer tracing & sintering a particular cross-section into a solid mass &
dust is taken off.
Another layer of powder is now deposited and this cycle is repeated
again and dust is shaken off
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Schematic illustration of the selective-laser-sintering process.

Source: After C. Deckard and P. F. McClure

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ii. Additive Process - Solid

d. Laminated object manufacturing (LOM )
Uses layer of papers or plastic sheets with
heat activated glue on one side of the
product parts
Excess material to be removed manually
Simplified by preparing the laser to burn
perforations in cross-sectional pattern
LOM uses sheets as thin as 0.05mm

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(a) Schematic illustration of the laminated-object-manufacturing process.

(b) Crankshaft-part examples made by LOM.
Source: (a) Courtesy of Helsis, Inc. (b) After L. Wood.

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iii. Virtual Prototyping

Modeling and simulation of all aspects of a prototype by a
realistic visualization.
All aspects of design processes such as mechanical design,
kinematics, dynamics, and controls.
Simple type use complex software & 3D graphics routines to
change the view on a computer screen.
Complicated versions use virtual-reality headgear and gloves
with appropriate sensors.
Advantages;
Instantaneous rendering of parts, where the best design in the
shortest lead-time of complex products/processes
Allows the exotic, unconventional designs be prototyped,
rapidly and cost-effectively

More advanced systems used very costly.

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2.0 Applications of Rapid Prototyping

Production of individual part
RP can be used to manufacture marketable
products directly especially involve the
polymer parts.
Pattern used in investment casting also
produced with RP techniques shown below

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Investment Casting Using Rapid-Prototyped Wax

Parts

Manufacturing steps for investment casting that uses rapid-prototyped wax parts as blanks.
This method uses a flask for the investment, but a shell method also can be used. Source:
Courtesy of 3D Systems, Inc.
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3.0 Rapid Tooling

Rapid Tooling (RT) is a process which either uses a
RP model as a pattern to create a mould quickly or
uses the RP process directly to fabricate a tool for a
limited volume of prototypes.
Advantages;
a) Tooling time is much shorter than for a conventional tool.
b) Tooling cost is much less than for a conventional tool.
c) Tool life is considerably less than for a conventional tool.
d) Tolerances are wider than for a conventional tool.

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Rapid Tooling for a Rear-Wiper

Motor Cover

Rapid tooling for a rear-wiper motor cover.

Source: Courtesy of 3D Systems, Inc.
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Advantages of Rapid Prototyping

Reduce product development time and cost
Get products to market sooner
Enhance communications between marketing,
engineering, manufacturing, and purchasing
Present physical model at critical design reviews
Perform functional prototype testing before
committing to tooling
Generate precise production tooling

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Disadvantages of Rapid Prototyping

Investment cost very high
Maintenance cost too high
Limitation on materials availability

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Any questions??

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In Class Activity
ALL students need to list down the differences of these
processes (and submit in GROUP):
Supply phase

Layer creation
technique

Phase change
type

Materials used

Stereolithography
Fused Deposition
Modeling
Selective Laser
Sintering (SLS)
Laminated object
manufacturing
(LOM)
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