CHAPTER 19

Rapid-Prototyping Operations

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 Rapid Prototyping Examples

Figure 19.1 (a) Examples of parts made

by rapid prototyping processes. (b)
Stereolithography model of cellular
phone.

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 Characteristics of Rapid Prototyping
Technologies
TABLE 19.1
Layer creation
Supply phase Process technique Phase change type Materials
Liquid Stereolithography Liquid layer curing Photopolymerization Photopolymers (acrylates
epoxies, colorable resins,
filled resins)
Solid-based curing Liquid layer curing Photopolymerization Photopolymers
and milling
Fused-deposition Extrusion of melted Solidification by Polymers
modeling polymer cooling (ABS,polyacrylate, etc.)
wax, metals and ceramics
with binder.
Ballistic-particle Droplet deposition Solidification by Polymers, wax
manufacturing cooling
Powder Three-dimensional Layer of powder and No phase change Ceramic, polymer and me
printing binder droplet powders with binder.
deposition
Selective laser Layer of powder Laser driven sintering Polymers, metals with
sintering melting and binder, metals, ceramics a
solidification sand with binder.
Solid Laminated-object Deposition of sheet No phase change Paper, polymers.
manufactuning material

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 Figure 19.2 The
computational
steps in
producing a
stereolithography
file. (a) Three-
dimensional
description of
part. (b) The part
is divided into
slices (only one in
10 is shown). (c)
Support material
Stereo- is planned. (d) A
set of tool
lithography directions is
determined to
manufacture each
slice. Shown is
the extruder path
at section A-A
from (c), for a
fused-deposition-
modeling
operation.

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 Fused-Deposition-Modeling
(a) (b)

Figure 19.3 (a) Schematic illustration of the fused-

deposition-modeling process. (b) The FDM 5000, a
fused-deposition-modeling-machine. Source:
Courtesy of Stratysis, Inc.

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 Common Support Structures

Figure 19.4 (a) A part with a protruding section which requires support material. (b) Common support
structures used in rapid-prototyping machines. Source: P.F. Jacobs, Rapid Prototyping &
Manufacturing: Fundamentals of Stereolithography. Society of Manufacturing Engineers, 1992.

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 Stereolithography

Figure 19.5 Schematic

illustration of the
stereolithography
process. Source: Ultra
Violet Products, Inc.

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 Example of Stereolithography
Figure 19.6 A two-
button computer
mouse.

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 Selective Laser Sintering

Figure 19.7 Schematic illustration of the selective laser sintering process. Source: After C.
Deckard and P.F. McClure.

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 Solid-Base Curing
Figure 19.8 Schematic illustration of the solid-base-curing process. Source: After M. Burns,
Automated Fabrication, Prentice Hall, 1993.

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 Three-Dimensional Printing
Figure 19.9
Schematic
illustration of
the three-
dimensional-
printing
process.
Source: After
E. Sachs and
M. Cima.

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 Laminated-Object Manufacturing

(a) (b)

Figure 19.10 (a) Schematic illustration of the laminated-object-manufacturing process. Source:

Helysis, Inc. (b) Crankshaft-part example made by LOM. Source: After L. Wood.

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 Investment
Casting

Figure 19.11 Manufacturing steps for investment casting that uses rapid--
prototyped wax parts as blanks. This approach uses a flask for the
investment, but a shell method can also be used. Source: 3D Systems, Inc.

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 Sand Casting Using Rapid-Prototyped Patterns

Figure 19.12 Manufacturing steps in sand casting that uses rapid-prototyped

patterns. Source: 3D Systems, Inc.

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 Sand Casting (continued)

Figure 19.12
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 Rapid Tooling
Figure 19.13 Rapid
tooling for a rear-
wiper-motor cover

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