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Applications of rapid prototyping


Rapid Prototyping
A family of fabrication processes developed to make engineering prototypes in minimum lead time based on a CAD model of the item Rapid prototyping allows a part to be made in hours or days, given that a computer model of the part has been generated on a CAD system.

Why is Rapid Prototyping Important?

Product designers want to have a physical model of a new part or product design rather than just a computer model or line drawing
*Creating a prototype is an integral step in design. *A virtual prototype may not be sufficient for the designer to visualize the part adequately. *Using RP to make the prototype, the designer can see and feel the part and assess its merits and shortcomings.

Two Basic Categories used in RP:

1. Material removal RP.

machining, using a dedicated CNC machine that is available to the design department on short notice. 2. Material addition RP.
Adds layers of material one at a time to build the solid part from bottom to top .

Alternative names for RP:

Layer manufacturing

Direct CAD manufacturing

Solid freeform fabrication Rapid prototyping and manufacturing.

RP technologies are being used increasingly to make production parts and production tooling, not just prototypes

Classification of RP Technologies.
The RP classification used here is based on the form of the starting material:
1. Liquid-based 2. Solid-based

3. Powder-based

RP technology in coin industry.

*In coin industry system using CAD/CAM, CNC

and RP technologies. *Similar to the jewelry industry. *It has traditionally increase regarded labor intensive and crafts based.

Steps followed
1st step - 2D art work has read into art cam and cad cam system. 2nd step - generation of the surfaces.(shape of the coin generated) 3rd step - generation of the relief(each color assign in the shape profile) 4th step - wrapping of the 3D relief on to the coin surfaces.(triangular mesh generate on the coin surface). 5th step convert the triangular mesh file in to STL file format. (this is to be used for building the RP model)

1. Design. 2. Engineering analysis and planning . 3. Tooling and manufacturing.

Design Applications
I. Reduced lead times to produce prototypes.

II. Improved ability to visualize part geometry.

III. Early detection of design errors .

Engineering Analysis and Planning

a) Comparison of different shapes and styles to determine aesthetic appeal b) Wind tunnel testing of streamline shapes c) Stress analysis of physical model

d) Fabrication of pre-production parts for process planning and tool design

Tooling Applications
Two approaches for tool-making:
1. Indirect RTM method 2. Direct RTM method

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