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RAPID

PROTOTYPING

INTRODUCTION

LAST CLASS DISCUSSED

About Product Development Process,

Step by step Process involved in PDP,

Where the prototype plays major role in
PDP,

Basics of Rapid Prototyping(RP),

Various Needs of RP system,

CONTENTS OF THIS PRESENTATION

Classification of RP system,

Fundamental fabrication Process,

Basic Process of RP system,

Impacts of RP and its tooling in Product
Development process,

 Solid based RP systems.CLASSIFICATION OF RP SYSTEMS  Liquid based RP systems.  Powder based RP systems. .

 Rapid Freeze Prototyping (RFP).  Solid Ground Curing (SGC). .  Solid creation system (SCS).LIQUID BASED RP SYSTEMS  Stereolithography Apparatus (STL).  Solid Object Ultraviolet-Laser Printer (SOUP).

LIQUID BASED RP SYSTEMS .

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 Multi-Jet Modeling System (MJM).  Fused Deposition Modeling (FDM). .  Melted Extrusion Modeling (MEM).  Paper Laminated Technology (PLT).SOLID BASED RP SYSTEMS  Laminated Object Manufacturing (LOM).

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 Direct Shell Production Casting. .  Three Dimensional Printing.  Electron Beam Melting Process.  Direct Metal Laser Sintering (DMLS).  Laser Engineered Net Shaping.POWDER BASED RP SYSTEMS  Selective Laser Sintering (SLS).

POWDER BASED RP SYSTEMS .

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FUNDAMENTAL FABRICATION PROCESS  Subtractive  Formative  Additive .

one starts with a single block of solid material larger than the final size of the desired object and portion of the material are removed until. .SUBTRACTIVE  In a subtractive process.

FORMATIVE  The formative process is one where mechanical forces or restricting forms are applied on a material so as to form it into the desired shape. .

.ADDITIVE  An additive process is the exact reverse in that the end product is much larger than the material when it started . materials are manipulated so that they are successively combined to form it into the desired shape.

building.STL file in CAD in RP systems Build Supports if needed RP Process Build Prototype Post Process Remove Supports Clean Surface Post Cure if needed Slicing Part Completed . and post processing CAD Model Pre Process Surface/Solid Model Generate .BASIC PROCESS OF RP Three stages: pre-processing.

 Solid modelers.  This process is identical for all of the RP build techniques. tend to represent 3-D objects more accurately than wire-frame modelers such as AutoCAD. such as Pro/ENGINEER.CAD MODEL CREATION  First. . and will therefore yield better results. the object to be built is modeled using a Computer-Aided Design (CAD) software package.

the first RP technique) format has been adopted as the standard of the rapid prototyping industry. Increasing . they cannot represent curved surfaces exactly. is to convert the CAD file into STL format. This format represents a three-dimensional surface as an assembly of planar triangles. therefore.CONVERSION TO STL FORMAT  To establish consistency. the STL (stereolithography.  STL files use planar elements.  The second step.

CONVERSION TO STL FORMAT .

CONVERSION TO STL FORMAT .

File menu-save copy As 2. then select yes 4.Maximum seg to 0.Select STL command 2.Click save.Select the model. CATIA 1.Select Export.CONVERSION TO STL FORMAT   Auto Desk 1.Select STL from the types drop down 3. ok.Check options-choose high(for quality surface) 4. .015mm 3.

 The pre-processing software slices the STL model into a number of layers from 0. a pre-processing program prepares the STL file to be built. 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.01 mm to 0. internal cavities.SLICE THE STL FILE  In the third step.7 mm thick. .

SLICE THE STL FILE .

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 Most machines are fairly autonomous. paper.  RP machines build one layer at a time from polymers. . needing little human intervention. or powdered metal.LAYER BY LAYER CONSTRUCTION  The fourth step is the actual construction of the part.

LAYER BY LAYER CONSTRUCTION .

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This involves removing the prototype from the machine and detaching any supports. sealing. .CLEAN AND FINISH  The final step is post-processing. and/or painting the model will improve its appearance and durability.  Some photosensitive materials need to be fully cured before use  Prototypes may also require minor cleaning and surface treatment.  Sanding.

CLEAN AND FINISH .

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IMPACT OF RAPID PROTOTYPING AND TOOLING IN PRODUCT DEVELOPMENT .

. So there is a possible to compress the over all product development time  It can greatly reduce the TIME-TO-MARKET  Reducing the part reducing assembly. count and thereby .CONT.  Time  In saving (CAD & CAE) Rapid Prototyping the different design and manufacturing activities are carried out concurrently..

 The manufacturer can reduce the labour content of machining/casting.CONT...  The main savings are in costs.  The product designers can increase part complexity with little significant effects on lead time and cost. . waste disposal cost.  It can greatly reduce material waste.

CONCLUSION OF THE PRESENTATION  About Classification of RP systems. Solid and Powder based systems.  Process involved in Liquid.  Impacts of RP and its tooling in Product Development process.  Fundamental Fabrication Process.  Basic Process of RP system. .

THANK YOU .