International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 5, September–October 2016, pp.117–126, Article ID: IJMET_07_05_014

Available online at
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=5
Journal Impact Factor (2016): 9.2286 (Calculated by GISI) www.jifactor.com
ISSN Print: 0976-6340 and ISSN Online: 0976-6359
© IAEME Publication

FUTURE OF MANUFACTURING TECHNOLOGY

RAPID PROTOTYPING TECHNIQUE
Yembadi Koushik Varma
B. Tech, Mechatronics (Mechanical) Engineering Department,
Mahatma Gandhi Institute of Technology, Hyderabad, India

Samatham Madhukar
B. Tech, Mechanical Engineering Department,
VidyaJyothi Institute of Technology, Hyderabad, India

Bootla Akhil
B. Tech, Mechanical Engineering Department,
VidyaJyothi Institute of Technology, Hyderabad, India

Pokala Saiprasanna Kumar

B.Tech, Mechanical Engineering Department,
Joginpally B.R Engineering College, Hyderabad, India

ABSTRACT
The term “Rapid Prototyping” (RP) refers to a class of technologies that can automatically
construct physical models from computer-Aided Design (CAD) data or is a group of techniques used
to quickly fabricate a scale model of a physical part or assembly using three-dimensional computer
aided design (CAD) data. . The edges and surfaces of a complex solid model and their information
are used for defining a product which is further manufactured as a finished product by CNC
machining. They make excellent visual aids for communicating ideas with co-workers or customers
apart from design testing. Across the world, Engineering has the common language and common
goal-“Improving the Quality of Life” of mankind without any boundary restrictions. The common
goal can be attained by the engineers in less time by RAPID PROTOTYPING TECHNIQUE and this
paper provides a better platform for researchers, new learners and product manufacturers for
various applications of RP models. Subsequently it creates awareness among the peoples of recently
developing RP method of manufacturing in product design, developments and its applications. A
review is undertaken in this paper for the different types of rapid prototyping techniques
Key words: Rapid Prototyping, computer aided design, product design.
Cite this Article: Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala
Saiprasanna Kumar, Future of Manufacturing Technology Rapid Prototyping Technique.
International Journal of Mechanical Engineering and Technology, 7(5), 2016, pp. 117–126.
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=5

http://www.iaeme.com/IJMET/index.asp 117 editor@iaeme.com

 Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala Saiprasanna Kumar

1. INTRODUCTION
Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate a scale model of a
part or assembly using three-dimensional computer aided design (CAD) data. What is commonly considered
to be the first RP technique, Stereo lithography, was developed by 3D Systems of Valencia, CA, USA. The
company was founded in 1986, and since then, a number of different RP techniques have become available.
Rapid Prototyping has also been referred to as solid free-form manufacturing, computer automated
manufacturing, and layered manufacturing. RP has obvious use as a vehicle for visualization. In addition,
RP models can be used for testing, such as when an airfoil shape is put into a wind tunnel. RP models can
be used to create male models for tooling, such as silicone rubber molds and investment casts. In some cases,
the RP part can be the final part, but typically the RP material is not strong or accurate enough. When the
RP material is suitable, highly convoluted shapes (including parts nested within parts) can be produced
because of the nature of RP.[1] There is a multitude of experimental RP methodologies either in development
or used by small groups of individuals. In recent years, an industry of producing three dimensional models
directly from 3D CAD data has grown rapidly. Several companies produce machines that can fabricate a
physical three-dimensional model out of various materials including plastic, paper and metal. Generally, the
machines run unattended and quickly produce an accurate model directly from CAD data without the need
for a highly skilled model-maker or machinist. These machines are generally known as rapid-prototyping
machines and the industry that has developed around these machines is called the rapid-prototyping industry.
These methods are unique in that they add and bond materials in layers to form objects. Such systems are
also known by the general name free form fabrication (FFF), solid freeform fabrication (SFF) and layered
manufacturing. Rapid prototyping is the automatic generation of 3D free-form shapes from virtual 3D
models is a crucial process in contemporary design and manufacture of commercial products. Current
modeling applications are limited in that they may only generate a small subset of all realizable 3D shapes
automatically. Typically only smooth and simple surfaces can be quickly designed using the latest Computer-
Aided Design (CAD) software such as AutoCAD or Computer-Aided Modeling (CAM) software. Modeling
complex shapes using these software packages requires a large amount of time. In these cases Rapid
Prototyping is used to create the model within minimum time. Rapid prototyping isn't a solution to every
part fabrication problem. After all, CNC technology is economical, widely understood and available, offers
wide material selection and excellent accuracy. However, if the requirement involves producing a part or
object of even moderately complex geometry, and doing so quickly - RP has the advantage. It's very easy to
look at extreme cases and make a determination of which technology route to pursue, CNC or RP. For many
other less extreme cases the selection crossover line is hazy, moves all the time, and depends on a number
of variably-weighted, case dependent factors. While the accuracy of rapid prototyping isn't generally as good
as CNC, it's adequate today for a wide range of exacting applications. The materials used in rapid prototyping
are limited and dependent on the method chosen. However, the range and properties available are growing
quickly. Numerous plastics, ceramics, metals ranging from stainless steel to titanium, and wood-like paper
are available. At any rate, numerous secondary processes are available to convert patterns made in a rapid
prototyping process to final materials or tools.

2. AIMS OF RAPID PROTOTYPING

• To increase effective communication.
• To decrease development time.
• To decrease costly mistakes.
• To minimize sustaining engineering changes.
• To extend product lifetime by adding necessary features and eliminating redundant features
• Rapid Prototyping decreases development time by allowing corrections to a product to be made early in the
process. By giving engineering, manufacturing, marketing, and purchasing a look at the product early in the
design process, mistakes can be corrected and changes can be made while they are still inexpensive.

http://www.iaeme.com/IJMET/index.asp 118 editor@iaeme.com

 Future of Manufacturing Technology Rapid Prototyping Technique

• The trends in manufacturing industries continue to emphasize the following:

• Increasing number of variants of products.
• Increasing product complexity.
• Decreasing product lifetime before obsolescence.
• Decreasing delivery time.
• Rapid Prototyping improves product development by enabling better communication in a concurrent
engineering environment.

3. PRINCIPLE OF RAPID PROTOTYPING

Rapid prototyping works on the basis of adding or removing layers of material to form the desired shape.
The majority of commercial rapid prototyping system build object by adding one layer after another. For
simplicity, it can be visualized as stacking slices of bread until complete three-dimensional bread loaf is
achieved. Rapid prototyping is a highly automated layer manufacturing process. The object is designed in
any solid modeling software (CAD) and the data is converted into a standard format widely known as
standard triangularisation language (STL) which is understandable by the rapid prototyping machine.[2]
Rapid prototyping software receives data in this format and creates a complete set of instructions for
fabrication on rapid prototyping machine such as tool path, layer thickness, processing speed, etc. Rapid
Prototyping machine then manufactures the object using layer manufacturing method. Upon completion of
a three-dimensional model, it is subjected to post processing treatment for removing support material that
was used to support overhang features during fabrication.

4. BASIC STEPS IN RAPID PROTOTYPING

Basic steps in all the RP techniques employ the same basic five step process. The steps are as follows:
1. Create a CAD model of the design 2. Convert the CAD model in to STL format 3. Slice the STL model
in to thin cross sectional layers. 4. Construct the model one layer atop another’s. Clean and finish the model.
CAD Model Creation: First the object to be built is modeled using a Computer added (CAD) software
package. A large number of software packages are available in the market like PRO/ENGINEER. These tend
to represent 3D models more accurately than the wireframe modelers such as AutoCAD and hence produce
very good results. The designer can create a new file expressly for prototyping or may use the existing CAD
file. The process is same for all the RP build techniques.
Conversion to STL Format The various CAD packages use a number of different algorithms to
represent solid objects. To establish consistency, the STL (stereo lithography, the first RP technique) format
has been adopted as the standard of the rapid prototyping industry. 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, "like the facets of a cut jewel. The file contains the coordinates of the vertices and the direction of
the outward normal of each triangle.[3] Because STL files use planar elements, they cannot represent curved
surfaces exactly. Increasing the number of triangles improves the approximation, but at the cost of bigger
files size. Large, complicated files require more time to pre-process and build, so the designer must balance
accuracy with manageability to produce a useful STL file. Since the STL format is universal, this process is
identical for all of the RP build techniques
Slice the STL File In the third step, a pre-processing program prepares the STL file to be built. Several
programs are available, and most allow the user to adjust the size, location and orientation of the model.
Build orientation is important for several reasons. First, properties of rapid prototypes vary from [4]one
coordinate direction to another. For example, prototypes are usually weaker and less accurate in the z
(vertical) direction than in the x-y plane. In addition, part orientation partially determines the amount of time
required to build the model. Placing the shortest dimension in the direction reduces the number of layers,
thereby shortening build time. 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

http://www.iaeme.com/IJMET/index.asp 119 editor@iaeme.com

 Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala Saiprasanna Kumar

overhangs, internal cavities, and thin walled sections. Each PR machine manufacturer supplies their own
proprietary pre-processing software.
Layer by Layer Construction The fourth step is the actual construction of the part. Using one of several
techniques (described in the next section) RP machines build one layer at a time from polymers, paper, or
powdered metal. Most machines are fairly autonomous, needing little human intervention.
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.

5. CLASSIFICATION OF RAPID PROTOTYPING PROCESSES:

The professional literature in RP contains different ways of classifying RP processes. However, one
representation based on German standard of production processes classifies RP processes according to state
of aggregation of their original material and is given in figure

Figure 1 Classification of Rapid Prototyping Processes

Some of the important process in rapid technology are of
Major RP Technologies:
• Photo Masking or Solid Ground Curing technique.
• SLS (Selective Laser Sintering)
• FDM (Fused Deposition Modelling)
• LOM (Laminated Object Manufacturing)
• 3D Printing
• Solid ground curing
• Thermo Jet Process
• Contour crafting

http://www.iaeme.com/IJMET/index.asp 120 editor@iaeme.com

 Future of Manufacturing Technology Rapid Prototyping Technique

6. APPLICATIONS OF RAPID PROTOTYPING

Rapid prototyping is widely used in the automotive, aerospace, medical, and consumer products industries.
Although the possible applications are virtually limitless, nearly all fall into one of the following categories:
• Prototyping
• Rapid tooling or rapid manufacturing.
a) Direct tooling
b) Indirect tooling

• Rapid Manufacturing

6.1. Proto Typing

As its name suggests, the primary use of rapid prototyping is to quickly make prototypes for communication
and testing purposes. Prototypes dramatically improve communication because most people, including
engineers, find three-dimensional objects easier to understand than two-dimensional drawings. Such
improved understanding leads to substantial cost and time savings by exchanging prototypes early in the
design stage, manufacturing can start tooling up for production while the art division starts planning the
packaging, all before the design is finalized. Prototypes are also useful for testing a design, to see if it
performs as desired or needs improvement. Engineers have always tested prototypes, but RP expands their
capabilities. [5] First, it is now easy to perform iterative testing: build a prototype, test it, redesign, build and
test, etc. Such an approach would be far too time-consuming using traditional prototyping techniques, but it
is easy using RP.

6.2. Rapid Tooling

A much-anticipated application of rapid prototyping is rapid tooling, the automatic fabrication of production
quality machine tools. Tooling is one of the slowest and most expensive steps in the manufacturing process,
because of the extremely high quality required. Tools often have complex geometries, yet must be
dimensionally accurate to within a hundredth of a millimeter. [6]In addition, tools must be hard, wear
resistant, and have very low surface roughness (about 0.5 micrometers root mean square). To meet these
requirements, molds and dies are traditionally made by CNC-machining, electro-discharge machining, or by
hand. All are expensive and time consuming, so manufacturers would like to incorporate rapid prototyping
techniques to speed the process. Peter Hilton, president of Technology Strategy Consulting in Concord, MA,
believes that "tooling costs and development times can be reduced by 75 percent or more" by using rapid
tooling and related technologies. Rapid tooling can be divided into two categories,
• Indirect Tooling: Most rapid tooling today is indirect: RP parts are used as patterns for making moulds and
dies. RP models can be indirectly used in a number of manufacturing processes a) vaccum casting b)sad
casting 3)investment casting 4)injection casting etc
• Direct Tooling: To directly make hard tooling from CAD data is the Holy Grail of rapid tooling. Realization
of this objective is still several years away, but some strong strides are being made:a) Rapid tool b)LOM
composite c)sand mouldingetc

6.3. Rapid Manufacturing

A natural extension of RP is rapid manufacturing (RM), the automated production of salable products Global
Journal of Computer Science and Technology. In 1996 Rubbermaid produced 30,000 plastic desk organizers
from a SLS-built mold. This was the first widely sold consumer product to be produced from direct rapid
tooling. Extrude Hone, in Irwin PA, will soon sell a machine, based on MIT’s 3D Printing process that
produces bronze-infiltrated PM tools and products directly from CAD data. Currently only a few final
products are produced by RP machines, but the number will increase as metals and other materials become
more widely available. RM will never completely replace other manufacturing techniques, especially in large

http://www.iaeme.com/IJMET/index.asp 121 editor@iaeme.com

 Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala Saiprasanna Kumar

production runs where mass-production is more economical. For short production runs, however, RM is
much cheaper, since it does not require tooling. RM is also ideal for producing custom parts tailored to the
user’s exact specifications. A University of Delaware research project uses a digitized 3-D model of a
person’s head to construct a custom-fitted helmet. NASA is experimenting with using RP machines to
produce spacesuit gloves fitted to each astronaut’s hands. [7] From tailored golf club grips to custom
dinnerware, the possibilities are endless. The other major use of RM is for products that simply cannot be
made by subtractive (machining, grinding) or compressive (forging, etc.) processes. This includes objects
with complex features, internal voids, and layered structures. Specific Surface of Franklin, MA uses RP to
manufacture complicated ceramic filters that have eight times the interior surface area of older types.[8] The
filters remove particles from the gas emissions of coal-fired power plants.5 Theirs, Inc. of NYC is using
RP’s layered build style to develop "pills that release measured drug doses at specified times during the day"
and other medical products.

7. GENERAL APPLICATIONS
Here are list of some of the generalised applications which we can see in our day to day life.

7.1. Medical Application

The RP model plays the vital role in medical applications. It is used in human facial scull transparency in
the medical field. Figure 3 shows the damaged portion of the human facial scull. Figure 2 shows the damaged
portion of the facial scull has been replaced by the RP model. [9, 10]

Figure 2 Damged facial scull replaced by RP Model Figure 3 Human damaged facial scull

7.2. Textile Application

The RP techniques models are widely used in textile industries. The complicated contour profile dresses are
designing in the 3D model with aid of computer and directly inter connected with manufacturing machine.
Figure 4 shows the RP model dresses with complicated contours.

http://www.iaeme.com/IJMET/index.asp 122 editor@iaeme.com

 Future of Manufacturing Technology Rapid Prototyping Technique

Figure 4 Modeled by RP

7.3. Electronic Application

The house holding electrical appliances are widely manufactured in the PR techniques. These RP techniques
are very useful for manufacturing the special contours in an electrical item.[11] Figure 5 shows the RP
models of electrical appliances.

Figure 5 RP Model of an electrical appliances

http://www.iaeme.com/IJMET/index.asp 123 editor@iaeme.com

 Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala Saiprasanna Kumar

7.4. Foot-Ware Design

The foot-ware for a human comfort is manufacturing in RP technique. This type of foot-ware should have
light weight and stronger than the conventional model. And also the complicated design of foot-ware is
developed in the RP technique models without any fastener. The reliability of the RP model is very high
compared with conventional model.[12]

Figure 6 RP Model of Foot-ware

7.5. Furniture Design

The furniture is designed and manufacturing with a aid of RP techniques. This model has low weight and no
temporary and permanent joints. It is made up of a single piece without any joints with different profiles.
Figure 7 shows the furniture model developed in the RP technique.

Figure 7 RP Model of Furniture

http://www.iaeme.com/IJMET/index.asp 124 editor@iaeme.com

 Future of Manufacturing Technology Rapid Prototyping Technique

8. CHALLENGES ASSOCIATE INSIGHT IN RAPID PROTOTYPING

The following are the challenges associate insight in rapid prototyping. The RP models are manufacturing
directly from the computer aided design model with automated machine. Hence, the following are to be
considered for developing the RP system. a) Develop automatic recognition of appropriate geometric
features from the STL file, such as; minimum wall thickness b) Develop the rules relating to prototyping
metal components. c) Improve the user definition or classification of prototype use. d) Investigate which
method of delivery best answer the needs of small companies and who would be responsible for its upkeep’s)
Create a full system in a native programming environment suitable for delivery in the manner identified.
[13]

9. FACTORS TO BE CONSIDERED WHILE DEVELOPING RP TECHNIQUES IN

INDIAN SCENARIO
The following are the factors to be considered for developing the RP techniques in Indian scenario. a) Initial
investment Cost b) Availability of trained people c) Knowledge in the automatic system d) Availability of
material e) Programming language f) Awareness of RP techniques g) Reality of the model h) Knowledge in
the 3D modeling i) Selection of Modeling software [14]

10. FUTURE DEVELOPMENTS

Rapid prototyping is starting to change the way companies design and build products. On the horizon,
though, are several developments that will help to revolutionize manufacturing as we know it. One such
improvement is increased speed. "Rapid" prototyping machines are still slow by some standards. By using
faster computers, more complex control systems, and improved materials, RP manufacturers are dramatically
reducing build time. As the Rapid Prototyping Technology gets further advanced, it can lead to substantial
reduction in build-up time for manufacturing.
• 1. Further improvement in laser optics and motor control can improve the accuracy.
• 2. The development of new materials and polymers so that they are less prone to curing and temperature
induced war Pages.
• 3. Much anticipated development is the introduction of non-polymeric materials including metals, ceramics,
composites and powder metallurgy.
• 4. Developments in ceramic composites can further increase the range of rapid prototyping.
• 5. Currently, the size is also a restriction; capability for larger parts shall be expected in the near future.
• 6. Currently, the demand is low and with the further technology advancement, awareness and training, this
can be increased.
• 7. Advancement in computing systems and viability to support net designs from a distant country to be fed
directly on the RP machines for manufacturing is a new possibility.

11. CONCLUSION
RP is one of the fastest growing new technologies of manufacturing the various products by adding the
material in layer by layer and directly from the 3D CAD model connected with the automated machine. This
paper deals with the various RP model related to the field of applications. This paper provides a platform for
researchers, new learners and product manufacturers to create an awareness of rapid prototyping and
manufacturing technology for creating the complicated and different contour products in various field of
applications. The various points are discussed in this paper for the researchers to insight the challenges
associate in rapid prototyping. However, some of the factors are given for developing the RP techniques in
Indian scenario.

http://www.iaeme.com/IJMET/index.asp 125 editor@iaeme.com

 Yembadi Koushik Varma, Samatham Madhukar, Bootla Akhil and Pokala Saiprasanna Kumar

REFERENCE
[1] D. T. Pham, S. S. Dimov, Rapid Manufacturing: the Technologies and Applications of Rapid Prototyping
and Rapid Tooling, Springer, London, 2001.
[2] D. King, T. Tansey, Alternative materials for rapid tooling. Journal of Materials Processing Technology,
Vol. 121, 2002, pp. 313–317
[3] . P. F. Jacobs, Stereo lithography and other RP&M Technologies: From Rapid Prototyping to Rapid
Tooling, ASME Press, New York, 1996.
[4] D. T. Pham, R. S. Gault, A comparison of rapid prototyping technologies. International Journal of
Machine Tools & Manufacture, Vol. 38, 1998, pp. 1257– 1287.
[5] H. Yang, D. Xue, Recent research on development Web-based manufacturing systems: a review.
International Journal of Production Research, Vol. 41, No. 15, 2003, pp. 3601–3629.
[6] H. B. Lan, K. S. Chin, J. Hong, Development of a teleservice system for RP service bureaus. Rapid
Prototyping Journal, Vol. 11, No. 2, 2005, pp. 98–105. 1. Cooper, K.G., Rapid Prototyping Technology,
Marcel Decker Publishing, New York, 2001.
[7] Prinz, F.R., Ed., Site Reports Vol. I, II, JTEC/WTEC panel on rapid prototyping in Europe and Japan,
Baltimore, MD: Loyola College, NTIS Rep. #PB96-199583, 1997
[8] Beaman, J.J., Barlow, J.W., Bourell, D.L., Crawford, R.H., Macrus, H.L., McAlea, K.P., Solid Freeform
Fabrication: A New Direction in Manufacturing,” Boston, Kluwer Academic Press, 1997.
[9] C. K. Chua, K. F. Leong, K. H. Tan, F. E. Wiria, C. M. Cheah, Development of tissue scaffolds using
selective laser sintering of polyvinyl alcohol/hydroxyapatite bio composite for craniofacial and joint
defects. J. Mater. Sci. Mater. Med., Vol. 15, No. 1, 2004, pp. 113–1121.

[10] Raju B S, Chandra Sekhar U and Drakshayani D N, Web Based E- Manufacturing of Prototypes by Using
Rapid Prototyping Technology. International Journal of Mechanical Engineering and Technology
(IJMET), 4(2), 2013, pp.32–38.
[11] N. K. Vail, L. D. Swain, W. C. Fox, T. B. Aufdlemorte, G. Lee, J. W. Barlow, Materials for biomedical
applications. Mater.Des., Vol. 20, 1999, pp. 123–132. [15] O. Abdelaal, S. Darwish, Fabrication of Tissue
Engineering Scaffolds Using Rapid Prototyping Techniques. World Academy of Science, Engineering
and Technology, International Science Index 59, Vol. 5, No. 11, 2011, pp. 1325 – 1333.

[12] Rahul M. Sherekar and Anand N.Pawar, A Review: Rapid Prototyping Techniques for Designing and
Manufacturing of Customized Anatomical Implants. International Journal of Mechanical Engineering
and Technology (IJMET), 5(3), 2014, pp.77–90.
[13] L. Novakova - Marcincinova, J. Novak - Marcincin, Testing of Materials for Rapid Prototyping Fused
Deposition Modelling Technology. World Academy of Science, Engineering and Technology,
International Science Index 70, Vol. 6, No. 10, 2012, pp. 396 - 399.
[14] R. Patil, S. Kumar, S. Ajmera, Bioengineering for Customized Orthodontic Applications - Implant,
Bracket and Dental Vibrator. World Academy of Science, Engineering and Technology, International
Science Index 72, Vol. 6, No. 12, 2012, pp. 1291 - 1295.
[15] Campbell, I., ed., Rapid Prototyping Journal, Emerald Journals, Bradford, UK. 13. Ghee, S., “The Virtues
of Visual Products,” Mechanical Engineering, pp. 60-64, June 1998.
[16] Sharke, P., “Rapid transit to Manufacturing,” Mechanical Engineering, pp. 63-66, March 2001. [15].
Thilmany, J., “Printing in Three Dimensions,” Mechanical Engineering, pp. 58-61, May 2001. [16].
Thilmany, J., “Walkabout in another World,” Mechanical Engineering, pp. 98-101, Nov., 2000. [17]. Orfe,
G., Publisher, Table of RP Distributors, Time Compression Technologies, July/Aug, pp. 5759, 2001.

http://www.iaeme.com/IJMET/index.asp 126 editor@iaeme.com