Rapid Prototyping

Introduction (RP in PD)

• Product Development is a complicated process.
• The role of prototyping in product development is very
important.
• There are many reasons why a prototype is important in
product development.
1.First we want to have a physical product to show to an investor
R or when seeking management approval
E 2.Another reason could be to test if a certain idea really works
A
S and to test if this design passes the requirements.
O 3.You can also use this prototype to evaluate the product and see
N
S if any further improvement is required.
4.Lastly, you can test the prototype on your market and analyze
their feedback. (Marketing Purpose)
Contn..

• A prototype is the first, full scale and functional form of a new product
design.
• It is used for investor demonstrations, testing, and gives your audience a
product to visualize and interact with.
• Prototypes are not production quality and should not be held to the same
standards of the final product.
• Prototypes help you learn what features need improvement, so you can
quickly perfect your product and get it to market.
• The journey from concept to market is typically a long road riddled with
hidden obstacles and unforeseen turns.
• Building a quick prototype of a design can help smooth that path as well
as present some substantial benefits.
Contn..

• The competition in the world market for manufactured

products has intensified tremendously in recent years
• It has become important for new products to reach the
market as early as possible, before the competitors
• To bring products to the market , many of the processes
involved in the design, test, manufacture and market of the
product have been squeezed, both in terms of time and
material resources
• This is mainly a result of the rapid development and
advancement in such technologies over the last few decades
Prototyping in Product development

• In product development, time pressure has been a major

factor in determining the direction and success of developing
new methods and advanced technologies
• There are several advantages to producing a prototype of
your product before going on to production.
• The first and most obvious is that a having prototype allows
you to see the actual product assembled
• It allows you to check the design, to touch it and see how the
whole thing fits together
• If there are any problems or design flaws you can then make
the changes you require
• A prototype is created.
• It is tested and improved until it is fully functional and suitable
for customer and purpose.
• The final product is then released
• Prototypes allow you to test the structure and function
• Prototypes are also a useful tool for generating interest and
investment in your idea
• A lot of companies will not even entertain you without a
prototype
• If you only have a few drawings scribbled however neatly and
accurately on a piece of paper you are selling yourself short
• Imagine the impact you could have with a fully functional
prototype.
 Definitions

• An original or first model of something from which other

forms are copied or developed
• A first or early example that is used as a model for what
comes later
• A prototype is an early sample, model, or release of a product
built to test a concept or process or to act as a thing to be
replicated or learned from
• In the product development process, one of the key steps is
creating a sample of the product before it is manufactured.
• A prototype is an initial creation of a product that shows the
basics of what a product will look like, what the product will
do, and how the product operates.
• Rapid Prototyping (Manufacturing) is the tool used in product
design
• Rapid prototyping takes your idea out of the computer and
into the real world

Magic printer
Converting 2D to 3D
Direct scale or working model

Idea to Reality
No of Iteration

A prototype is an initial creation of a product that shows the basics of what a

product will look like, what the product will do, and how the product operates
Steps : A prototype is created.
Conventional to Rapid Prototyping It is tested and improved until it is fully functional and
suitable for customer and purpose.
The final product is then released
 Benefit of a Prototype
• A prototype is a valuable tool in the product development
process.
• It gives the inventor or the creator a chance to see their idea
come to reality.
• The prototype is essentially a rough draft of the product. Once
the prototype is created, steps can be taken to refine the
product, both in design and function.
• During prototyping, you’re not just testing out what you’re
making, you’re also validating how you’re going to make
it. (Test manufacturing processes)
• Prototypes may be used to demonstrate a potential product
and can also be used as a tool to gain financing or
investments.
• When a potential investor can see what the item is you want
to create, they can get a better vision of what you want to
produce and may be more interested in putting their money
towards the project.
• Reduce costs – Any modification you make during the
prototyping phase – whether to product design, materials, or
manufacturing processes – could help you save cost on the
final product.
• Greater design flexibility, with the ability to run quickly
through multiple design iterations
• Fewer production design flaws and better end-products
 Different types of prototype
• Visual prototype (size & appearance)
• Functional prototype (test a concept)
• Presentation prototype (Function + Appearance)
• Pre-Production prototype (Checking Manufacturability)
• Miniature / Scale Model prototype (scaled)
 Different types of prototype

‘Visual prototype’ - This type of prototype conveys the overall

shape and size of the product but does not usually prove the
function of the idea.
It is not designed to represent the materials or production
methods of a final mass produced product.
• Display prototypes are designed with more focus on the look
and feel of the product rather than the functions.
• These prototypes may or may not function but represent the
look of the actual product very well.
Functional or proof of concept prototype
• Functional prototypes are designed to imitate the functions of
the actual product as closely as possible, no matter how
different they look from the actual product.
• These types of prototypes are produced for the products
which are dependent on the function rather than the display.
• This form of model will demonstrate how the product works,
providing functional validation.
A prototype that demonstrates the main functionality of the
idea.

Demonstration of the practical implementation of any

method, idea, technology or feasibility in order to prove the
fact that the method, idea or technology works
‘Presentation’ prototype.

• This type of prototype combines the functionality of

the product with the overall appearance. it is likely
that production grade materials will be used.
‘Pre-Production’ prototype(Factory Sample)

This type of prototype builds on the work of a presentation

prototype by fully considering mass production
manufacturing methods and production. The parts are likely
to be created using production methods and materials.

The objective of the pre-production prototype is to check the

manufacturing processes and techniques required to produce
the product

Knowledge about the manufacturability of the product

‘Miniature / Scale Model‘ prototype
• Sometimes a product is too big to drag around to meetings,
like a structure (house, apartment building, etc.) or a
vehicle. In this case, a model is usually built to scale.

Miniatures are smaller versions or the basic versions of the product focused on
both the functional aspect as well as the display aspect.
Nevertheless, these aren’t the actual products and lack many qualities of the
actual product like not working at full capacity, etc.
Product Development is a complicated process.
• The role of prototyping in product development is very
important.
• Benefits of a Prototype (refine the product(design&function),
Gives chance to inventor to see their idea come to reality, tool to get finance, greater deign
flexibility , minimum design flaws )

• Different types of prototype(visual, functional, presentation, pre-

production & miniature)
• Visual prototype (size & appearance)
• Functional prototype (test a concept)
• Presentation prototype (Function + Appearance)
• Pre-Production prototype (Checking Manufacturability)
• Miniature / Scale Model prototype (scaled)
• Product is developing something, which is useful for the customer
• Design is a way of thinking
• So product design is Thinking divergently, making iteratively-right at
first time
• Rapid Prototyping (Manufacturing) is the tool used in product design
• The product design process has experienced huge evolution over the
last few years with the rise and adoption of 3D printing
• Rapid prototyping takes your idea out of the computer and into the
real world

Many geometry Final Product

•
Iteration Many material
Many colour

So PD + RP =PDRP
Lets brief about Mft
 Traditional Methods (Earlier, old)

Manufacturing Input Processes Out Put

Raw material Useful Product
Conversion of raw materials in to useful product

● Manufacturing process can be additive, subtractive, or formative

● Casting
● Machining Traditional Methods
● Forming
● Joining

Very less scope for iteration in traditional methods

 NonTraditional Methods (Latest. new)

Rapid Prototyping
SUBTRACTIVE ADDITIVE
Create parts by removing  Build objects by adding material
material
Layer by layer material is added
Layer by layer material is

one over another to develop
gradually removed from a solid
block to fabricate 3-D product. desired solid 3-D product
More waste
 Minimum waste


CNC
 3D Printing

 Subtractive Manufacturing (RP) (CNC)
You want to make a sphere...
The really old way: Take a block of material and carve it
out

The more modern way:

• Generate CNC program

• Machine away unwanted
material
 Additive Manufacturing (RP)(3D Printing)
• Generate a 3D model
• Software slices the 3D model
into thin slices
• Machine builds it layer by layer

Both can be rapid prototyping

Popularly additive manufacturing is called RP
 What is RAPID PROTYPING?

Group of techniques used quickly to fabricate a

scale or working model of a physical part using
three-dimensional computer aided design data

Magic printer
Converting 2D to 3D
Direct scale or working model
•Defined as process that automatically create physical prototype from 3D
CAD model in a short period of time
•Suppose if u design a CAD model, the same part comes out of printer

•If u design a relative motion part –gives the print command – the part

comes out of printer

•Here parts are built by adding layer by layer
Two Important Considerations

• Time compression
• In the world scenario, the product, which arrives first in the
market, always stands to gain.
• The conventional method of product development takes
considerable amount of time to bring out the first prototype
• Buyers v/s Seller market

28
 Need for Time compression in PD

• In his book Business @ speed of thought Bill Gates states that

• “If the 1980’s were about quality and the 1990’s about re-
engineering, then the 2000’s will be about velocity”.
• To achieve velocity within organizations, time compression is
required in all processes
• Customers are increasingly taking low cost and higher quality
for granted, and moving their attention to the availability of
the product or service as soon as the need arises
• This change in customer requirements is forcing businesses to
become much more agile (quick) in adapting their products
and processes to changing market demand
• Leading edge companies have recognized that competitive
advantage can only be gained by the application of time
compression within the design and operation of supply chain
processes

• Time compression is not about making people work faster,

thereby risking quality, safety and their livelihoods

• Instead, time compression is about the removal of wasted

time throughout the business, which generally results in
improved customer satisfaction, reduction in inventory levels
and increased quality
• In the quest for fast manufacturing, all non-productive times
need to be eliminated
• The traditional method involves time loss on concept
designing, manufacturing, assembly and testing.
• For example, in case of a foundry, lot of time is spent on
pattern designing, making, getting the casting done and then
evaluating its performance.
This initially involves designing and redesigning, until a
satisfactory product is developed, which is a very slow process
• Slow process- Optimum design is difficult
 Prototyping to Rapid Prototyping
• Prototyping is what has been used for decades to design, develop,
and create accurately scaled models of various products.
• This method requires years of training and can take many days to
complete.
• Here traditional methods are used
• Time consuming
• Rapid prototyping is a relatively new term and, in its simplest
form, creating a prototype quickly to visually and functionally
evaluate a part or some part features.
• Sometimes individual parts are rapidly created separately and
assembled to test the prototype product.
• Rapid prototyping is a group of techniques used to quickly
fabricate a scale model of a physical part or assembly
 Time Compression by RP

• Rapid prototyping (RP) has emerged as a key enabling

technology, with its ability to shorten product design and
development time
• Rapid prototyping is a means of compressing the time-to-
market of products and, as such, is a competitiveness
enhancing technology
• In this age of fast growth (rapid technology age), customer
demands are increasing rapidly . Customers do not like to
wait.
• The traditional processing time needs to be shortened.
• It is a‘Buyers market’ today, instead of a ‘Sellers market’ as it
used to be in the past
• A market which has more sellers than buyers. Low prices
result from this excess of supply over demand
• Thus, in order to survive in this buyers market; technological
advancements are essential to meet the buyers demand as
well.
• Nowadays, the market is no longer the seller’s market which
used to be few decades ago, that means whatever the
manufactures produce in whatever timeframe, the customers
are supposed to consume those or buy those products.
• They do not have the flexibility or choice to go for a product
of their choice at their own time, which was called or referred
to as seller’s market
• But nowadays the scenario is changing totally.
History of Rapid Prototyping
• Rapid prototyping is quite a recent invention. The
first machine of rapid prototyping hit the markets in
the late 1980s.
• Rapid prototyping in its earlier days was applied to production
of models and prototype parts.
• But nowadays with the advancement in technology, rapid
prototyping is used widely for many applications that include
manufacturing production-quality parts.
• The manufacturing of these quality parts however are very
small in numbers.
• Apart from industrial applications, rapid prototyping is also
used in sculpting.
• The application of rapid prototyping in sculpting is to generate
fine arts exhibitions
• The development of RP is closely tied in with the development
of applications of computers in the industry

• The declining cost of computers has altered the way a factory

works

• The increase in the use of computers has made advancement in

many computer related ares including CAD, CAM and CNC

• In particular, the emergence of RP systems could not have been

possible without the existence of CAD
• Manual prototyping by a skilled craftsman has been an age-
old practice for many centuries
• Second phase of prototyping started around mid-1970s,when
a soft prototype modeled by 3D curves and surfaces could be
stressed in virtual environment, simulated and tested with
exact material and other properties
• Third and the latest trend of prototyping, i.e., Rapid
Prototyping (RP) by layer-by-layer material deposition, started
during late 1980s with the enormous growth in Computer
Aided Design and Manufacturing (CAD/CAM) technologies
History Of RP
Year of inception Technology
1770 Mechanization (the introduction of machines or automatic devices into a
process, activity)
1946 First computer
1952 First Numerical Control (NC) machine tool (automated control
of machining tools by means of a computer)
1960 First commercial laser ( Cutting , Joining )
1961 First commercial Robot (a machine which is programmed to move and
perform certain tasks automatically. ...)
1963 First interactive graphics system (communication between the
computer and the user)
1988 First commercial Rapid Prototyping system (3D Printer)
THREE PHASES OF DEVELOPMENT LEADING TO
RAPID PROTOTYPING
• MANUAL PROTOTYPING ( First Phase)
• SOFT or VIRTUAL PROTOTYPING( Second phase)
• RAPID PROTOTYPING (of physical parts)( Third)

• “Solid freeform fabrication”,

• “Desktop manufacturing” or
• “LayermanufacturingTechnology”
Phase First : Manual prototyping
• Prototyping had begun as early as human started to develop
tools to help them live
• Prototyping as applied to products began several centuries
ago
• In this early phase, prototypes typically are not very
sophisticated and takes on average about four weeks
• The techniques used in making these prototypes tend to be
craft-based and are usually extremely labor intensive
Phase Second : Soft or Virtual prototyping

• An application of CAD/CAE/CAM become more widespread,

the early 1980s saw the evolution of the second phase of
prototyping – Soft or Virtual Prototyping
• Virtual prototyping takes on a new meaning as more
computer tools become available
• Computer models can now be stressed, tested, analyzed and
modified
• For example, analysis of stress and strain can be accurately
predicted on the product because of the ability to specify
exact material attributes and properties

• With such tools on the computer, several iterations of designs

can be easily carried out by changing the parameters of
computer models
Phase Third: Rapid Prototyping
• RP or solid free-form fabrication or layer manufacturing
technology , represents the third phase in the evolution of
prototyping
• Because of this methodologies tremendous time savings,
especially for complicated and difficult to produce models
• Though parts are relatively three times as complex as parts
made in 1970s, the time required to make such a part now is
too less
• Since 1988, more than 30 different RP techniques have
emerged and commercialized
Group of techniques used quickly to fabricate a scale or working model
of a physical part using three-dimensional computer aided design
data
Rapid prototyping is quite a recent invention (model to actual)
Two Important Considerations
History of Rapid Prototyping
1770-Mechanization
1946-First computer
1952-First Numerical Control (NC) machine tool
1960-First commercial laser
1961-First commercial Robot
1963-First interactive graphics system
1988-First commercial Rapid Prototyping system (3D Printer)

THREE PHASES OF DEVELOPMENT LEADING TO RAPID PROTOTYPING

MANUAL PROTOTYPING ( First Phase)
SOFT or VIRTUAL PROTOTYPING( Second phase)
RAPID PROTOTYPING (of physical parts)( Third)
 Fundamentals Of Rapid Prototyping

RP technique comprise of two general types

• Subtractive RP

• Additive RP

• Each of which has its own pros and cons

 Subtractive RP
• Subtractive manufacturing is an umbrella term for various
controlled machining and material removal processes that
start with solid blocks, bars, rods of plastic, metal, or other
materials that are shaped by removing material through
cutting, boring, drilling, and grinding.
• These processes are either performed manually (Lathe,
drilling ….) or by computer numerical control (CNC)
 Additive RP

• In contrast to the subtractive process of removing material

from a larger piece, additive manufacturing or 3D printing
processes build objects by adding material one layer at a time
• Each successive layer bonding to the preceding layer until the
part is complete.
• Material is added on or built up in the process to create the
shape of the final part.
 Subtractive Vs Additive
Subtractive Manufacturing
In subtractive manufacturing, layer by layer
material is gradually removed from a solid block
to fabricate 3-D product.
These processes are associated with material
wastage in the form of chips, scraps, dissolved
ions, vapors, etc.
Subtractive manufacturing processes have limited
capability in fabrication of complex shapes.
Structures containing enclosed hollow parts
cannot be produced by these processes, unless
joining is allowed.
Additive Manufacturing
In additive manufacturing, layer by layer material
is added one over another to develop desired
solid 3-D product.
No material wastage takes place in these
processes.
Complex shapes can be easily fabricated using
additive manufacturing techniques.
Structures containing fully closed internal hollow
parts can be produced by these processes.
Fundamentals Of Rapid Prototyping
• Additive type RP is the opposite of subtractive type RP. Instead of
removing material, material is added layer upon layer to build up
the desired design such as stereolithography, fused deposition
modeling (FDM), and etc
• Additive type RP can fabricate most complex geometries in a
shorter time and lower cost
• 3D printing, also known as additive manufacturing, is a method of
creating a three-dimensional object layer-by-layer using a
computer-created design. This means layers of material are built
up to create a 3D part.
• These "three dimensional printers" allow designers to quickly
create tangible prototypes of their designs, rather than just two-
dimensional pictures
• The technology works by adding layer upon layer of material to
build up a complete object.
• Rapid prototyping is a group of techniques used to quickly
fabricate a scale or actual model of a physical part or
assembly using three-dimensional computer aided design
(CAD) data.
• Construction of the part or assembly is usually done using 3D
printing technology.
• 2D Printing vs 3D Manufacturing : We are know technology of
printing two dimensional letters or some drawings on a sheet of
paper, that means we can produce some output on the plane
sheet of papers and that we can read, we can use, we can see.
• Essentially, the difference between 3D and 2D printers is that of
printing versus manufacturing.
 8 cm

=10 cm

• Printing produced in two dimensions which has got x and y dimension and we
are capable of reading it, using it, interpreting it
• Similarly 3D printing gave to the concept that we can build another
dimension into it.
• So build another dimension that is in the z direction, then this will give us
nothing but a 3 D product
• We obtain a 3 D product rather than a 2 D product. So, this is the background
or the basic of this process.
• 3D printing is the process of making an object out of some material, often
plastic. 2D printing, or just simply, printing, is the process of putting an image
or text on a paper
Steps in RP
Rapid prototyping is having a profound impact on the way
companies produce models, prototype parts and tooling.
A few companies are now using it to produce final
manufactured parts
Steps in RP
• 1 - Creation of the CAD model of the (part) design
• 2 - Conversion of the CAD model into Standard Tessellation
Language (STL) format
• 3 - Slicing of the STL file into thin sections
• 4 - Building part layer by layer
• 5 - Post processing/finishing/joining
Step 1

Step 2
Step 3

Step 5

Step 4
• Rapid systems quickly produce models and prototype parts
from model data may be 3 D model, CAD model, MRI scan
data and data created from 3 D digitizing systems. I
N
P
Software U
T
• 3D model- CAD model Scanner
Coordinate measuring machine
AutoCAD,freeCAD, Soild works, CATIA, Solid edge etc

• Using an additive approach to building shapes, RP systems

join liquid, powder, solid or sheet material to form physical O
objects U
T
P
U
• Layer by layer, RP machines fabricate plastic, wood, ceramic T
and metal powders using thin, horizontal cross sections of a
computer model.
 • The first step being a CAD model is to be produced
• Then followed by this in the second step this CAD model is
converted into STL format that is again the digital phase only
• Then this model is sliced into thin sections say for example, if
the product height is of 100 millimeter. This is to be sliced;
this height is to be sliced into suitable thicknesses, which can
be realized in one go of the machine.
• That means we can have 100 slices of 1 millimeter thick or
1000 slices of 0.1 millimeter thick and so on

100 slices each 1mm

100 mm
1000 slices each 0.1 mm
• 2D Printing Vs 3D Manufacturing
• Difference between 3D and 2D printers is that of printing versus manufacturing
Software I
N
• 3D model- CAD model Scanner P
Coordinate measuring machine U
T
AutoCAD,freeCAD, Soild works, CATIA, Solid edge etc

• Using an additive approach to building shapes, RP systems join liquid, powder, solid or O
sheet material to form physical objects U
T
• Layer by layer, RP machines fabricate plastic, wood, ceramic and metal powders using P
thin, horizontal cross sections of a computer model. U
Steps in RP T
• 1 - Creation of the CAD model of the (part) design
• 2 - Conversion of the CAD model into Standard Tessellation Language (STL) format
• 3 - Slicing of the STL file into thin sections
• 4 - Building part layer by layer
• 5 - Post processing/finishing/joining
• 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 too

complex shape easily as compared to traditional
manufacturing technology.

• RP helps in earlier detection and reduction of design

errors.
1. Create a CAD model of the design

2. Convert the CAD model to STL format

3. Slice the STL file into thin cross-sectional layers

4. Construct the model one layer a top another

5. Clean and finish the model

 CAD Model Creation:

• First, the object to be built is modeled using a Computer-Aided

Design (CAD) software package or coordinate measuring machine
or laser scanner.
• This process is identical for all of the RP build techniques.

AutoCAD,freeCAD, Soild works, CATIA, Solid edge etc

 Conversion to STL Format:
To establish consistency, the STL (stereo lithography, the first
RP technique) format has been adopted as the standard of
the rapid prototyping industry and acts as the interface b/w
CAD software and machines.
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 triangular facets.
The STL (Standard Triangle Language) is the industry
standard file type for 3D Printing
 Slice the STL File:
• The 3D model is then converted into machine language (G-code)
through a process called “slicing” and is ready to print.
• In this 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.
 Layer by Layer Construction:
• The fourth step is the actual construction of the part.
• RP machines build one layer at a time from polymers,
metal , paper, powdered metal etc.
• 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.

• If Support structure is used, detaching the same

How Does Rapid Prototyping Work
in product design
• In an engineering product design context, a
prototype is a preliminary version of the end-
product and used to
1. design
2. test the technology
3. analyse the working principle which in turn
provides
4. product specification for a real working system.
• Prototypes are an integral part of product design and more
importantly in an overall new product development process.
• Rapid prototyping can be used at any stage of the product
development cycle or for any component or sub-component
and can be repeated numerous times along the new product
design process.
• Engineering product design is changing as people are not
satisfied with just functional products anymore.
• They want it to look good, last longer and be in trend.
• They also want it to be cheaper
• The list is endless and it is changing and evolving all the time
along with the technological advancement in every field.
• For example couple of decades ago you wouldn’t dream of
dropping the phone in water, but these days people expect the
phone to be working and taking pictures while they get soaked
in the rain.
 Why is rapid prototyping
important?
• In this fast-moving modern-day consumer market,
companies need to develop and introduce new
products faster to remain competitive.

• Since faster product development and technology

innovation are key to a company’s success, rapid
prototyping becomes the most important element of
new product development.
 Why types in RP
• The success or failure of a prototype depends on your
selection of rapid prototyping processes for the new product
development.
• There are various ways in which engineering product design
prototypes can be made varying from simple cardboard mock-
ups to fully machined metal sub-assemblies.
• Each rapid prototyping technique has its own compromise in
terms of cost, speed, material compatibility of the feature,
fidelity level and development stage.
• So RP wheel gives total picture of RP process
 RP Wheel

Fundamentally, the development of RP

can be seen in four primary areas
 • 1-INPUT

• 2-MATERIAL

• 3-METHOD

• 4-APPLICATIONS
 1. INPUT
• Input refers to the electronic information required to describe
the physical object with 3D data.
• There are two possible starting points – a computer model or
a physical model.
• The computer model created by a CAD system
• On the other hand, 3D data from the physical model is not at
all straightforward.
• It requires data acquisition through a method known as
reverse engineering.
• In reverse engineering, a wide range of equipment such as
CMM or digitizer, to capture data points of the physical model
and “reconstruct” it in CAD system.
 2.MATERIAL

• The initial state of material can come in either

– solid, liquid or powder state.

• In solid state, it can come in various forms such

– Solid wire, powder, pellets or laminates.

• The range materials include

– paper, nylon, wax, resins, metals and ceramics.
 3 METHOD
• While they are currently more than 20 vendors for RP systems, the
method employed by each vendor can be generally classified into
the following categories:
– photo-curing (Photo curing is the process of hardening a substance by
exposing it to a specific wavelength of light)- SLA SGC
– cutting and glueing/joining (adhesive-coated paper, plastic, or metal
laminates as a 3D printing medium. These sheets of material are glued
together layer-by-layer and cut into shape using a knife or with laser cutting) -
LOM
– melting and solidifying/fusing and joining/binding.( i- creates parts
from plastic filament by melting and then depositing them in layers. ii) tiny
particles of plastic, ceramic or glass are fused together by heat from a high-
power laser to form a solid, three-dimensional object)-FDM, SLS
 4. APPLICATIONS

• Applications can be grouped into:

– Design

– Engineering, Analysis and Planning

– Tooling and Manufacturing

 Design
• This was the initial application area for RP systems.
• Designers are able to confirm their design by building a real
physical model in minimum time using rapid prototyping
• The features and functions of the part can be communicated to
others more easily using a physical model than by a paper
drawing or displaying it on a CAD system monitor
• Benefits to design attributed to rapid prototyping include :
(1)Reduced lead times to produce prototype components,
(2)Improved ability to visualize the part geometry because of
its physical existence
(3)Earlier detection and reduction of design errors and
(4)Increased capability to compute mass properties of
components and assemblies
 Engineering Analysis and Planning

• The existence of an RP-fabricated part allows for certain types

of engineering analysis and planning activities to be
accomplished that would be more difficult without the physical
entity
• Some of the possibilities are
(1)comparison of different shapes and styles to optimize
aesthetic appeal of the part
(2)analysis of fluid flow through different orifice designs in
valves fabricated by RP
(3) wind tunnel testing of different streamline shapes using
physical models created by RP
(4) stress analysis of a physical model
 Manufacturing and Tooling

• The trend in RP applications is toward its greater use in the

fabrication of production tooling and for actual manufacture
of parts.

• Alternate manufacturing process.

• Used for making tools.