Explain basic methodology for Rapid prototype process used as a manufacturing step in production.

1. A CAD model is constructed, then converted to STL format. The resolution can be set to minimize stair stepping.

2. The RP machine processes the .STL file by creating sliced layers of the model.

3. The first layer of the physical model is created. The model is then lowered by the thickness of the next layer, and the process is repeated until completion of the model.

4. The model and any supports are removed. The surface of the model is then finished and cleaned.


• High quality product is easily delivered by way of Rapid prototyping. Rapid prototyping proves to be cost effective.ADVANTAGES: • • Rapid Prototyping can provide with concept proof that would be required for attracting funds Active participation among the users and producer is encouraged by rapid prototyping As the development costs are reduced. • The speed of system development is increased. • • 2 . It is possible to get immediate feedback from the user There is better communication between the user and designer as the requirements and expectations are expressed in the beginning itself.

Explain the additive process for Rapid prototype and list 5 advantages of this process. In addition. RP techniques can also be used to make tooling (referred to as rapid tooling) and even production-quality parts (rapid manufacturing). 3 . These "three dimensional printers" allow designers to quickly create tangible prototypes of their designs. Rapid prototype is construct physical models from Computer-Aided Design (CAD) data. They make excellent visual aids for communicating ideas with co-workers or customers. prototypes can be used for design testing. rather than just two-dimensional pictures. Such models have numerous uses.

However. The multi-part capability also allows quite large single parts (e. in contrast to SLA.Solid Ground Curing: An Introduction Solid Ground Curing. Many parts can be created at once because of the large work space and the fact that a milling step maintains vertical accuracy. The overall process is illustrated in the figure above and the steps are illustrated below. the SGC process is considered a high-throughput production process. The SGC process uses photosensitive resin hardened in layers as with the Stereolithography (SLA) process. Wax replaces liquid resin in non-part areas with each layer so that model support is ensured. also known as the Solider Process.g. of Israel. The high throughput is achieved by hardening each layer of photosensitive resin at once. 500 × 500 × 350 mm / 20 × 20 × 14 in) to be fabricated. is a process that was invented and developed by Cubital Inc. 4 .

the photomask is positioned over the work surface and a powerful UV lamp hardens the exposed photosensitive resin: 5 . a photomask is produced using Cubital's proprietary ionographic printing technique. At the beginning of a layer creation step. First. as illustrated below: Next. as shown below: For each layer. a CAD model of the part is created and it is sliced into layers using Cubital's Data Front End® (DFE®) software. the flat work surface is sprayed with photosensitive resin.Solid Ground Curing Process The steps in the process are as follows.

solid support for the model as it is fabricated. leaving the hardened areas intact. The cured layer is passed beneath a strong linear UV lamp to fully cure it and to solidify any remnant particles.After the layer is cured. The wax is hardened by cooling to provide continuous. the wax/resin surface is milled flat to an accurate. In the final step before the next layer. Extra supports are not needed. all uncured resin is vacuumed for recycling. reliable finish for the next layer: 6 . as illustrated below: In the fifth step. wax replaces the cavities left by vacuuming the liquid resin.

can be performed.Once all layers are completed. and any finishing operations such as sanding. the wax is removed. No post-cure is necessary. 7 . etc.

The FDM process feeds filaments of build material and support material to heated nozzles. Once the first cross section is completed the build platform is lowered one layer thickness and the next cross section is printed. This process is continued until the part is completed. Once complete. 8 .Fused deposition modeling (FDM) Process using molten plastics or wax extruded by a nozzle that traces the parts crosssectional geometry layer by layer. heated extrusion nozzles and a nozzle control apparatus. filament feed devices. These nozzles are used to lay down molten filaments of build and support materials in the desired cross sectional geometries. An FDM machine consists of the following parts a build platform.FDM creates tough parts that ideal for functional usage. The whole system is contained within a heated environment to reduce the amount of energy needed to melt the filament at the nozzle. the part can be taken out and any support structures can be removed. The FDM rapid prototyping process is akin to using a hot glue gun to make parts.

The software slices the . CAD Models can be produced in about 24 hours depending on the size and complexity. A plastic filament is melted and extruded through a heated nozzle. and Z coordinate by using a heated material extrusion process. The nozzle moves to produce a profile of the part then moves down and the next layer is built on top until the entire prototype model is fully built. 3. 5. Y. The model needs to be imported into Stratasys’ software. PROCESS 1.How FDM Works The FDM fused deposition model process is additive which extrudes material in layers. 2. We are currently using ABS plus material. Online price quotes are available for FDM parts. The model is complete and requires no hardening. Insight. The system draws cross-sectional layers one at a time in the X. FDM is an excellent choice for any 3D Model that needs to closely represent the final product in strength and durability. a part model is created in a STL file with AutoCad or another design program. generating the required supports.stl file into horizontal layers mathematically. First. Insight creates tool paths required for the extrusion head. 9 . 4.

10 .Baillistic-Particle manufacturing (BPM) The BPM personal modeler came with all hardware and software enclosed in one compact unit. The BPM utilized ink jet or droplet based manufacturing techniques. The BPM is controlled by a DOS based 486 powered PC which is housed within the unit. the platform then lowers and the process is repeated for each layer of the model. where it builds the models by firing micro-droplets of molten wax material from a moving nozzle or jet onto a stationary platform.

molten plastic is fed to a piezoelectric jetting mechanism. using the jetting mechanism. thus saving companies enormous time and expense. almost like those of ink jet printers 2.) Next a multi-axis controlled NC (Numerical Control) system shoots tiny droplets of material onto the target. forming the surface particle by particle. where precision and durability as well as speed and flexibility are of critical importance. Paramount’s team of experts is now setting the standard in using laser sintering for additive manufacturing/rapid manufacturing. Beginning with rapid prototyping. Paramount was honored by Raytheon for its work in producing key components for an advanced mine-hunting sonar system and unprecedented supplier performance A)Selective Laser Sintering [SLC] 11 . and providing unprecedented flexibility in bringing new products to commercialization. rapid prototyping and additive manufacturing processes. In particular.PROCESS 1. Symbolizing this leadership. a leading-edge application that is generating finished parts direct from 3D CAD solid models. then progressing to rapid tooling. 3. Paramount’s expertise in laser sintering additive manufacturing has assisted OEMs of advanced-technology products for military applications.)Last. Selective Laser Sintering (SLS) Paramount Industries is widely recognized as a leader in innovative applications of Selective Laser Sintering (SLS) also known as Laser Sintering (LS) in the product development.) In the first step of the process. small droplets freeze upon contact with the surface.

Once this is done the part bed drops down the asset amount and the process continues from the opposite side with the other feed bed raising and hte roller distributing another layer of powder over the part bed and the laser etches out the shape.1mm) and the roller pushes the raised powder across.  With the layer of powder present the laser starts to etch out the desired shape of the part in the powder in effect melting the powder.PROCESS  A roller is positioned beside one of the feed beds. This feed bed then raises a set amount (Usually < 0. REFERENCE 12 . covering the part bed with a Powder Layer.

pdf 13 .th/~panya/461/RP_2550.efunda.psu. http://www. http://knowledge.wikipedia.com/activekb/questions/12/Solid+Ground +Curing 4.me.ac. www.org/wiki/R-process 2.com/processes/rapid_prototyping/sgc.cfm 3.stereolithography.1. http://en.

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