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Rapid Prototyping (RP)

Introduction of RP
Generate a prototyping by Laying Manufacturing Technology

Rapid Prototyping (RP)

Development of RP
First Phase : Manual (or Hard) Prototyping Age-old practice for many centuries Prototyping as a skilled craft is traditional and manual and based on material of prototype Natural prototyping technique

- composite material layer by layer Build in one step - directly from model to manufacturing

Rapid Prototyping (RP)

Development of RP
Second Phase : Soft (or Virtual) Prototyping Mid 1970s Increasing complexity Can be stressed, simulated and tested with exact mechanical and other properties

Rapid Prototyping (RP)

Development of RP
Third Phase : Rapid Prototyping Mid 1980s Hard prototype made in a very short turnaround time (relies on CAD modelling) Prototype can be used for limited testing prototype can consist in the manufacturing of the products 3 times complex as soft prototyping

Rapid Prototyping (RP)

Fundamentals of RP
Building computer model Model is building by CAD/CAM system Model must be defined as enclosed volume or solid Converting model into STL file format STereoLithography (STL) file is a standard format to describe CAD geometry used in RP system STL file file approximates the surfaces of the model by polygons

Rapid Prototyping (RP)

Fundamentals of RP
Fabricating the model Building model layer by layer Forming a 3D model by solidification of liquid/powder

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Rapid Prototyping (RP)

Applications of RP
For design evaluation Touch and holding a physical prototype For function verification e.g. assembly, kinematics performance, and aerodynamic performance Models for further manufacturing processes e.g. Vacuum casting, spray metal moulding, investment casting, etc.

Rapid Prototyping (RP)

Advantages and Disadvantages
No planning of process sequences No specific equipment for handling materials No transportation between machining Features-based design and feature recognition are

unnecessary
Defining a blank geometry is unnecessary Defining different setups or complex sequences of handling

material is unnecessary

Rapid Prototyping (RP)

Advantages and Disadvantages
No need to consider jigs and fixtures Designing and manufacturing moulds and dies Specific materials are restricted

Rapid Prototyping (RP)

Role of RP in Product Development Cycle
Product design Increase part complexity and diversity with little effect on lead time and cost Minimise time-consuming discussion and evaluations of manufacturing possibilities Tool design and manufacturing Minimise design, manufacturing and verification of tooling Reduce parts count and eliminate tool wear

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Rapid Prototyping (RP)

Role of RP in Product Development Cycle
Assembly and test Reduce labour content of manufacturing (e.g. machining, casting, inspection and assembly, etc.) Reduce material costs (e.g. handling, waste, transportation, spare and inventory, etc.) Function testing Avoid design misinterpretations, i.e. what you design is what get)

Rapid Prototyping (RP)

Due to the newness of the technology, there are already so

many words for RP used today:

RP( most commonly used) - Rapid Prototyping RPTM(inc. new development trends) - Rapid Prototyping,

Tooling and Manufacture

Direct CAD Manufacturing/Desktop Manufacturing/Instant

Manufacturing/CAD Oriented Manufacturing = RP

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Rapid Prototyping (RP)

Layer Manufacturing/Material Addition

Rapid Prototyping (RP)

Classification of RP Systems

Manufacturing/Material Deposit Manufacturing/ Material Increase Manufacturing/Solid Freedom Manufacturing Emphasis the unique characteristic of RP

By the initial form of its material, RP systems can be categorised into:

Liquid-based

Liquid-based material Curing Process Solid (e.g. SLA, SGC, SOUP, etc.)

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Rapid Prototyping (RP)

Classification of RP Systems
Solid-based

Rapid Prototyping (RP)

Features of RP Systems

Encompass all forms of material in the solid form, such as in the form of wire, a roll, laminates and pellets. (e.g. LOM and FDM, etc.) Powder-based Grain-like material Joining/Binding Solid (e.g. SLS and 3DP, etc.)

The features of some commercially available RP systems can be summarised into:

Process type - Stereo lithography, Laminating, Fused

deposition modelling, Sintering of powder, Solid ground curing, etc. Work space(mm) - depends on the models Material - photopolymer resin, coated paper, ABS, wax, metal alloy, etc.

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Rapid Prototyping (RP)

Features of RP Systems
Layer thickness(mm) - 0.05 - 0.3(SLA); 0.1 - 1(LOM.);

Rapid Prototyping (RP)

Pre-Processing Tasks
Prepare geometric model in STL file format

~0.05(FDM); ~0.08(SLS); 0.01 - 0.15(SGC) Accuracy(mm) - 0.01- 0.2(SLA); 0.1 - 0.2(LOM); 0.127 0.254(FDM); 0.03 - 0.38(SLS); 0.05 - 0.5(SGC) Manufacturer - 3D System, Stratasys, Helisys, DTM, EOS, etc.

Solid or surface CAD model to be built is next converted into format dubbed the .STL file format because it is a standard input data to any RP process. STL originates from 3D Systems, which pioneers the Stereolithography system in 1987. The format approximates the surfaces of the model using tiny triangles. Since 1990, almost all major CAD/CAM vendor supply the CAD-STL interface.

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Rapid Prototyping (RP)

Pre-Processing Tasks
Building up direction

Rapid Prototyping (RP)

Pre-Processing Tasks
Trapped volume

The direction affects many key aspects of RP process, quality of the surface finish, build time, amount of support structures needed, and amount of trapped volume. For experience, minimising the height of the geometry will reduce the no. of layers required, thereby decreasing build time, but also sacrifice part resolution or accuracy.

It is the amount of liquid resin in the RP process (e.g. SLA) that was entrapped by the processed or solidified region. Thus trapped volumes can exist in concave regions that as containers. It may be eliminated by either building a part with a drain hole and fill the hole after solidification or modifying the orientation of the part.

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Rapid Prototyping (RP)

Pre-Processing Tasks
Part placement

Rapid Prototyping (RP)

Pre-Processing Tasks
Support structure

In RP, the time spent building a prototype does not depend on the no. of parts but on the total no. of slices required. By closely packing multiple parts into feasible volume, several parts can be built at the same time.

The support structure in RP process has the following functions:

ensure the recoater blade will not strike the platform when the first

layer is swept
improve uniformity of layer thickness provide a simple means of removing the part from the platform upon

its completion

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Rapid Prototyping (RP)

Pre-Processing Tasks
Support structure

Rapid Prototyping (RP)

Post-Processing Tasks
Part removal and cleaning

However, overdesign of support structures results in added design and manufacturing time, as well as finishing operations

After a part is built, drain excess liquid resin at the platform and the part back into the vat. Next, the part and the platform are placed in a cleaning apparatus with solvent (e.g. TPM). It will produce little swelling distortion on a part. Once the part has been thoroughly cleaned of excess resin, both platform and part are rinsed with water to remove TPM film. The last step is to remove the part from the platform by flat-bladed knife.

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Rapid Prototyping (RP)

Post-Processing Tasks
Post curing

Rapid Prototyping (RP)

Principle of Stereolithography Apparatus (SLA)

During some RP processes, such as SLA, the laser scans each layer along the boundary and hatching lines only. This means that inside portions of the layers may not be completely solidified. Thus the part is post-cured to complete the polymerisation process by exploring with UV radiation in a specially designed apparatus.

SLA was developed in 1986 by 3D Systems. The process is based on the following principles:
Parts are built from a photo-curable liquid resin that

solidifies when sufficiently exposed to a laser beam which scans across the surface of the resin The building is done layer by layer, each layer being scanned by the optical scanning system and controlled by an elevation mechanism which lowers at the completion of each layer

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Rapid Prototyping (RP)

Post-Processing Tasks
Part finishing

Rapid Prototyping (RP)

Process of SLA

Step 1 -

This process is to remove the supports by using a dull edged blade or putty knife. Care must be taken to avoid damaging a part that contains fragile sections. Once the supports have been removed, minor sanding is applied to eliminate residual traces of the supports.

A liquid state photosensitive polymer that solidifies when exposed to a lighting source Step 2 A platform that can be elevated is located just one layer of thickness below the surface Step 3 According to the cross section of the part (starting with bottom layer). The laser scans the polymer layer above the platform to solidify the polymer

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Rapid Prototyping (RP)

Process of SLA

Rapid Prototyping (RP)

Applications of SLA
Models for conceptualisation, packaging and presentation Prototypes for design, analysis, verification and functional

Step 4 -

The Platform is lowered into the polymer bath to the layer thickness Step 5 Repeat 3 and 4 until the top layer of the part is generated Step 6 Post-curing and part finishing will then be performed

testing
Masters for prototype tooling and low volume production

tooling
Patterns for investment casting, sand casting and moulding Tools for fixture and tooling design and production tooling

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Rapid Prototyping (RP)

Principle of Selective Laser Sintering (SLS)

Rapid Prototyping (RP)

Principle of Selective Laser Sintering (SLS)
The building of the part is done layer by layer. Each layer of

SLS was developed by DTM Corporation in 1992. The process is based on the following principles:
Parts are built by sintering when a CO2 laser beam hit a thin

layer a powdered material. The interaction of the laser beam with the powder raises the temperature, resulting in particle melting and bonding together

the building process contains the cross sections of one or many parts. The next layer built directly on the top of the sintered layer after an additional layer of powder is deposited via a roller mechanism on the top of the previously formed layer

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Rapid Prototyping (RP)

Process of SLS

Rapid Prototyping (RP)

Process of SLS

Step 1 A part cylinder is located at the height necessary for a layer of powdered material to be deposited on the cylinder to the desired thickness. The powder is applied from the feed cylinder by the levelling roller

The layer of powder is selectively rasterscanned and heated with a laser, causing particles to adhere to each other. The laser scan forms the powder into the required cross section shape. Again this step starts with the bottom cross section Step 3 The part cylinder is lowered by the layer thickness to permit a new layer of powder to be deposited

Step 2 -

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Rapid Prototyping (RP)

Process of SLS

Rapid Prototyping (RP)

Applications of SLS
Concept models Functional models and working prototypes Wax casting pattern Polycarbonate patterns. These build faster than wax

Step 4 -

The new layer is scanned, conforming it to the shape of the next upper cross-section and adhering it to the previous layer Step 5 Repeat 3 and 4 until the top layer of the part is generated Step 6 Post-curing may be required for some material

patterns and are ideally suited for design with thin walls and fine features. These pattern are also durable and heat resistant Metal Tools. Direct rapid prototype of tools of moulds for small or short production runs.

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Rapid Prototyping (RP)

Process of FDM

Rapid Prototyping (RP)

Process of FDM

The process of FDM is relatively simple and fast but its use is limited to thermoplastic materials Step 1 The thermoplastic material in the form of filament is heated to just above its solidification temperature Step 2 The extrusion head is heated and moves according to the pattern of the cross section of each layer of the part

Step 3 -

The material is extruded on the foundation or previously built layer. As it is extruded, it is cooled and thus solidifies to form the required pattern of part Step 4 Repeat 2 and 3 until the top layer of the part is generated Step 5 Part finishing may be required

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Rapid Prototyping (RP)

Applications of FDM
Models for conceptualisation and presentation Prototypes for design, analysis and functional testing Patterns and masters for tooling. Models can be used as

Rapid Prototyping (RP)

Principle of Laminated Object Manufacturing (LOM)

LOM was developed by Helisys Inc. in 1991. The process is based on the following principles:
Parts are built, layer by layer, by laminating and laser-

patterns for investment casting, sand casting and moulding

trimming materials that are delivered in sheet form. The sheets are laminated into block by a thermal adhesive coating

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Rapid Prototyping (RP)

Process of LOM

Rapid Prototyping (RP)

Process of LOM

The accuracy of the process of LOM is high. The most popular laminated material is paper sheet. Step 1 Sheet material is supplied from a continuous roll form. Each sheet attached to the block, using heat and pressure to form a new layer Step 2 The platform is lowered by the thickness of the sheet whenever a sheet is attached to the stack

Step 3 -

After a layer is deposited, a CO2 laser is traced on the layer along the contours corresponding to the current cross section Step 4 Areas of the layer outside the contours are cross-hatched by the laser (i.e. cut into small pieces for removal afterwards)

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Rapid Prototyping (RP)

Process of LOM

Rapid Prototyping (RP)

Applications of LOM
Applicable for a wide range of product, equipment for

Step 5 After the part is built, the result is imbedded within a block of supporting material. This material is then broken into chunks along the cross-hatching lines Step 6 The resulting part may then be coated with a sealant to keep out moisture

aerospace or automotive, consumer products, and medical devices Prototypes for design, analysis and functional testing Tools for production Small volume of finished goods

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Rapid Prototyping (RP)

Principle of 3D Printing (3DP)
3DP was invented by MIT in 1994 Parts are created by a layered printing process and

Rapid Prototyping (RP)

Process of 3DP

adhesive bonding, based on sliced cross section data. A layer is created by adding another layer of powder. The powder layer is selectively joined, where the part is to be form, by ink-jet printing of a blinder material

The process of 3DP is more efficient and relatively cheaper than sintering types. Step 1 Platform is located at the height necessary for a layer of ceramic powder to be deposited Step 2 The layer of ceramic powder is selectively raster-scanned with a print head that delivers a liquid binder, causing particles to adhere to each other

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Rapid Prototyping (RP)

Process of 3DP

Rapid Prototyping (RP)

Process of 3DP

Step 3 -

Step 4 -

The platform is lowered by the layer thickness to permit a new layer of powder to be deposited The new layer is scanned, conforming it to the shape of the next upper cross section and adhering it to the previous layer

Step 5 Repeat 3 and 4 until the top layer of the part is generated Step 6 A post-process heat treatment is applied to solidify the part

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Rapid Prototyping (RP)

Applications of 3DP
CAD-Casting metal parts. A ceramic shell with integral

cores can be fabricated directly from the CAD model

Direct metal parts. It is adaptable to a variety of material

systems, allowing the production of metallic/ceramic parts with novel composition Prototypes with colours and elastic feature

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