Lesson 19

Rapid prototyping: Concept, Advantages

Dr. Inderdeep Singh

Department of Mechanical and Industrial Engineering

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 Rapid Prototyping
Prototype
• Originated from Greek word (1603),
prototypon "a first or primitive form,

" Protos “First" + Typos “Form”.

• It is an art of managing expectation.

• An original, full scale, and usually working

model of new product or new version of
existing product.

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 Rapid Prototyping
Historical development of Rapid Prototyping and related technology

Year of Inception Technology

1770 Mechanization
1946 First Computer
1952 First Numerical Control Machine
1960 First Commercial Laser
1961 First Commercial robot
1963 First Interactive Graphics System
1988 First Commercial Rapid Prototyping

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 Rapid Prototyping

Introduction
• 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 complex shape easily as

compared to traditional manufacturing technology.

• RP helps in earlier detection and reduction of design errors.

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 Rapid Prototyping Systems
All RP techniques employ the basic five-step 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 a-top another

• Clean and finish the model

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Rapid Prototyping System

Source-http://web.iitd.ac.in/~pmpandey/MEL120_html/RP_document.pdf
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 Rapid Prototyping System

CAD Model Creation:

• First, the object to be built is modelled using a Computer-Aided Design
(CAD) software package.

• Solid modellers, such as Pro/ENGINEER, tend to represent 3-D objects

more accurately than wire-frame modellers such as AutoCAD, and will
therefore yield better results.

• This process is identical for all of the RP techniques.

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 Rapid Prototyping System
Conversion to STL Format:

• The second step, therefore, is to convert the CAD file into STL format. This
format represents a three-dimensional 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

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 Rapid Prototyping System

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.

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 Rapid Prototyping Systems

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.

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 Rapid Prototyping System

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.

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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.

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 Advantages of Rapid Prototyping

• Post processing include only finishing and cleaning.

• Minimum material wastage.

• Reduces product development time considerably

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 Techniques of Rapid Prototyping

• SLA (Stereo Lithography)

• SLS (Selective Laser Sintering)

• LOM (Laminate Object Manufacturing)

• FDM (Fused Deposition Modelling)

Thank You