ENGIN3305

Manufacturing Engineering
Week 8
Commonwealth of Australia Copyright Act 1968
Notice for paragraph 135ZXA (a) of the Copyright Act 1968
Warning

This Material has been reproduced and communicated to you by or on behalf of Federation University Australia
under Part VB of the Copyright Act 1968 (the Act).
The Material in this communication may be subject to copyright under the Act. Any further reproduction or
communication of this material by you may be the subject of copyright protection under the Act.

Do not remove this notice.

Industrial manufacturing- Rapid
prototyping
DeGarmo’s Materials and Processes in Manufacturing
Product Cycle In Conventional Environment
Product Cycle In An Computerised Environment
Introduction

• Additive processes is new grouping of processes that create

a desired shape by the incremental addition of material in a
layer-by-layer fashion.
• As design concepts are transitioned from computer-aided
design models to working products, prototypes are often
produced.
• The manufacture of prototype products could be produced
with extremely short lead times; the term rapid prototyping
was commonly applied
Introduction

Rapid prototyping applications:

• Rapid prototyping of parts: building the shape progressively
through the accumulation of thin layers.
• Scale model making
• Rapid tooling
• Direct digital manufacturing
Introduction

Prototyping can be used for:

• Dimensional checking
• Functional testing
• Appearance checking
Rapid Prototyping and Direct-Digital
Manufacturing
Additive process – created layer by layer
• 3D CAD design (pre-processing)
• Converted into a tool path by CAM software
• Suitable machine to produce a layer by layer model
• Liquid-based
• Powder-based
• Deposition-based (solid)
• Removal of base, supports, uncured resin (post-processing)
 Framework for Rapid Prototyping

FIGURE 19-1a Conceptual framework for

additive processes: (a) development of a
virtual model in CAD;
Framework for Rapid Prototyping

FIGURE 19-1b Conceptual framework for

additive processes: b) model is converted
to STL file format and loaded into CAM
software;
Framework for Rapid Prototyping

FIGURE 19-1c Conceptual framework for additive

processes: (c) CAM software slices the model to generate
tool paths for the laser;.
 Framework for Rapid Prototyping

FIGURE 19-1d (d) product is

produced layer-by-layer in
machine too..
Framework for Rapid Prototyping

FIGURE 19-1e Conceptual

framework for additive
processes: (e) final prototype or
product.
General steps

(a) development of a virtual model in CAD;

(b) model is converted to STL file format and loaded into CAM
software;
(c) CAM software slices the model to generate tool paths for the
laser;
(d) product is produced layer-by-layer in machine tool;
(e) final prototype or product.

12
Stereolithography

FIGURE 19-2 The stereolithography apparatus (SLA) (right) can build a part (left) in plastic, layer by layer,
using a laser to polymerize liquid photopolymer. (Source: Cutting Tool Engineereng, December 1989.)
Layerwise Manufacturing

CAD/CAM method
Mostly uses stereolithography (STL) files
Accuracy and smoothness depends on the resolution of the
layering process.
Layerwise Manufacturing

1. Liquid-based processes.
2. Powder-based processes.
3. Deposition-based processes (or solid-based).

• All In general, the surface finish of the liquid-based processes

is better than that of the powder-based approaches.
• For certain applications, the as-deposited surface finish may
not be adequate. Secondary grinding, sanding, or polishing
may be required.

15
Stairstepping

The various additive manufacturing processes

produce products with a range of surface
finishes and surface textures, but all suffer
from a phenomenon known as stairstepping:

• All surfaces not perpendicular to the slice

plane

• Surface geometry, therefore, will tend to be

rougher in the z-direction than around the
perimeter of the x-y planes FIGURE 19-3 Building by layers results in
stairstepping of curved surfaces
and rounded corners.
 Build time vs. Thickness

however, decreasing the layer

thickness often results in an increase in the
time required to build the part

FIGURE 19-4 Build time

versus layer thickness for various laser power levels. (From P.F.
Jacobs, Rapid Prototyping
and Manufacturing: Fundamentals of
Stereolithography, SME, Dearborn, MI., 1992.)
Laser Curing

FIGURE 19-5 Schematic of a

generic laser-based additive
process showing the traditional
coordinate system.
Laser Curing Profile

FIGURE 19-6 In
stereolithography, the laser
produces a
cure line of photopolymer,
where the width, depth, area,
and profile are determined
by the voxel.
Supports in RP
FIGURE19-7 Many of the
additive manufacturing
processes require use of
a bases and supports.
Liquid-Based Processes

• A photocurable polymer (resin) is injected in layers along a

tool path following a CAD file.
• precise motion control,UV lasers.
• Very thin layers (in the micron range)
• Can be expensive
• Usually needs some post-processing
FIGURE19-8 (left) A honeycombed pattern (solid surface with
honeycomb interior) produced by stereolithography is used to
produce an investment casting (right) of particle-reinforced aluminum.
(Courtesy O’Fallon Casting)
Inkjet Deposition

• systems create the individual layers

by selectively depositing molten
material (wax, thermoplastic
polymers, or lowmelting-pointmetals)
onto a substrate as a series of
uniformly spaced, uniform-size micro
droplets, often at rates of several
thousand per second.
• As depicted in Figure 19-10,
thesedroplets then adhere to the
substrate, forming the new layer, and FIGURE 19-10 Inkjet deposition uses the ballistic part
concept to build solid objects.
ultimately a solid mass.
Powder-Based Processes

• Like most of the other processes, selective laser sintering

(SLS) and selective laser melting (SLM) begin with the same
CAD STL file as liquid method
• Uses a heat-fusible powder that is spread over the tool path
• A laser is then scanned over the layer to selectively fuse
together those areas defined by the cross-section geometry
• Fuses powder particles together including the layer beneath
• Unfused powder acts as a support to the part often leading to
no post-processing
Selective Laser Sintering

FIGURE 19-11 Selective laser sintering uses a laser to scan and sinter powdered material
into solid shapes in a layer-by-layer manner.
FIGURE 19-12 Half of a silica sand casting mold produced by selective
laser sintering. (Courtesy of Mr. C. S. Huskamp, St. Louis, MO.)
selective laser sintering (SLS)

• Selective laser sintering uses one of the broadest range of

build materials, including plastics, waxes, metals, ceramics,
and particulate composites
• Strength, toughness, and elongation values are among the
best of the additive manufacturing processes and are often
near isotropic.
• The porosity of these materials may be as much as 40% of
the part volume.
• Semicrystalline materials, such as nylon, are locally melted
and can essentially produce fully dense parts

27
FIGURE 19-13 Comparison of metal lprototype manufacture by CNC machining
and direct-digital manufacture using selective laser sintering. Note the significant
reduction in total process time. (Courtesy of Mr. C. S. Huskamp, St. Louis, MO.)
Electron Beam Manufacturing Process

FIGURE 19-15 Small metal impeller made from titanium

FIGURE 19-14 Schematic of the electron beam
(Ti-6Al-4V). (Arcam AB)
manufacturing process.
Three-Dimensional Printing

• In yet another approach, inkjet

printing has been combined with
powdered materials by using the
inkjet to deposit a liquid binder.
• An inkjet printing head then scans
the powder surface and selectively
injects a binder material joining the
powder together. FIGURE 19-16 Three-dimensional
printing builds components by
• As in selective laser sintering, the selectively binding powdered material
unbounded powder remains inplace, in a layer-by-layer manner. Metal parts
are then sintered and possibly
surrounding the product and serving infiltrated to produce strong, high-
density products.
as supports.
FIGURE 19-17 A casting mold produced by binding
sand using three-dimensional printing, and the
aluminum casting that was made in the mold.
(Courtesy of Z-Corporation)
3D Printing

3D Printing is a form of Additive Manufacturing

• Process of joining materials to make an object
• From 3D model Data; layer-by-layer process

Type of Additive Manufacturing

• SLA (Sterolithography)
• SLS (Selective Laser Sintering)
• FDM (Fused Deposition Modeling)
• DLP (Digital Light Processing

32
Fused Deposition Process

FIGURE 19-18 Schematic of

fused deposition modeling. This
process can be “office friendly”
(i.e., small in size and using
nontoxic materials).
Deposition-Based Processes

Fused deposition modelling

• Laminated 3D objects via extrusion of thermoplastic material
• Each layer is fused to the previous
• Similar to an x – y plotter
• Simpler process than the previous two
• Limited selection of working material
Laminated Object Manufacturing

FIGURE 9-19 Schematic of the laminated object manufacturing process where solid sheets are used
to create the layers.
Uses and Applications

Converts design to a physical representation

• Evaluate concepts
• Comparison through multiple iterations before manufacture
• Detect and correct design errors
• Assess assembly, alignment, size
• Some functional testing
• Communication model (show and tell to management)
• Sales and marketing tool
• Reduces product development time
FIGURE 19-20 Example of additively produced prototypes used to assess
form, fit, and function. An assembly of components and SLS prototypes
(including engine, exhaust headers, and active suspension) has been prepared
for wind tunnel testing of an open-wheeled race car.
FIGURE 9-21 Assembly of small-scale models produced directly from CAD data by
additive manufacturing processes. (Courtesy of Mr. C. S. Huskamp, St. Louis, MO.)
FIGURE 9-22 Titanium
skull patch produced by
the electron beam melting
process beginning with
data obtained from a CT
scan of an injured person.
This is an example of a
one-of-a-kind, or custom,
product. (Arcam AB)
Economic Considerations

• Reduction of development and operating costs

• Faster response to customer requests
• Improved product development
• Improved process development – reduction of lead times
• Lower cost for small batch size
Thank you

43