Rapid Prototyping / Rapid Tooling

Rapid Prototyping (RP) refers to the physical modeling of a design using a special class of machine technology. The input to these Rapid Prototyping machine is an output format from a CAD data called *.STL Using additive approach to building shapes, RP systems join liquid, powder or sheets of materials to form physical objects.
(The entire process is Simple & Automatic)
RP Machine

*.STL file

*.SLI file

CAD Data The model is created in any CAD Software and saved as STL file.

RP Software

The model is sliced in Z axis of uniform thickness which creates an SLI file.

The SLI model is fabricated in layer by layer starting from bottom to top.

Major Technologies
Selective Laser Sintering (SLS)

3D CAD Data
Not Suitable Format
Paper draw

Suitable Format
CAD-Volume-Model

D2-CAD-Model

3D-CAD-Suface-Model

Layer Generation
.STL data

.SLI format

Building Process

Major Technologies
Selective Laser Sintering (SLS) Scanner Recoater Optics Laser

Loose Powder Part

Frame Platform Loose Powder

3D-Printing Technique (3DP)

3D Printing is a Rapid Prototyping technique
The sectional and solid-drawing of the component constructed using any standard drawing software are acceptable The drawing need to be converted to STL (stereo-lithographic) file format

The process step consists of printing the component layer by layer on a bed of finely dispersed powder with intermittent chemical and thermal curing of the formed layer
Subsequent to each layer being created, the platform supporting the powders bed incrementally moves down, this enables the creation of the second layer. Unique Features: A range of complicated shapes can be created (e.g. undercuts, internal cooling channels, conjoined/concentric parts) Flexibility (one can buildup a cylinder in both vertical as well as horizontal axis position Prototype Material can be normal strength polymer; a flexible elastomer, or a high strength material. Potential Application: As an educational and research tool; For rapid tooling

For prototype component fabrication Jobbing

3D-Printer

Miniature gear (80 m thickness) being printed

Cleaning & Recycling Chamber

Top-View and Solid Drawing of Gear-1

Top-View and Solid Drawing of Gear-2

Gear-1 and Gear-2 were stacked one on top of another

A separation of 160 m was left by leaving the polymer particles uncured so as to facilitate subsequent separation of the two parts Total printing time taken [Gear-1 (35 min); Gear-2 (40 min)]

Primary Cleaning of After Part Fabrication

Subsequent to this the parts were further cleaned in air-blow chamber. The loose powders was collected through air-suction The cleaned parts were resin infiltrated (optional step) to impart greater strength to the prototype

Prototype Parts

40 mm

Prototype Part

10 mm
Part thickness: 240 m

Prototypes Fabricated in Engineering Metallurgy Lab

20 mm

Unassembled
Both components fabricated simultaneously

Assembled

Prototypes Fabricated in Engineering Metallurgy Lab

10 mm