RAPID PROTOTYPING

Debabrata Das
 Topic Overview
• Introduction
• Basic Principal of Rapid Prototyping
• Rapid Prototyping chain Process
• Classification of Rapid Prototyping
• Stereo Lithography
• Rapid Freeze prototype
• Selective Laser sintering
• 3D printing
• Fused Deposition Modelling
• Conclusion
• References
Rapid Prototyping (RP) is a method in which the part is created by a layer
additive process
Using a specialized software, a 3D CAD model is generated and sliced into very
thin layers or cross- sections
RP machine constructs the part layer by layer until a solid replica of the CAD
model is generated
• the part is fabricated by deposition of layers contoured in a (x-y) plane two
dimensionally.
• The third dimension (z) results from single layers being stacked up on top of
each other.
 RP Process Chain
Classification of RP
Supply /Input build materials phase

Liquid Powder Solid

Stereo Selective laser Laminated object

lithography(SLA) sintering(SLS) manufacturing(LOM)

Solid ground 3 dimensional Fused Deposition

curing(SGC) printing(3DP) Modelling(FDM)

Rapid Freezing Laser Engineered Net

(RF) Shaping(LENS)
Stereo lithography Apparatus (SLA)

•Invented by Charles W. Hull

• The first commercial RP
system
• Use photo-curable liquid resins
• Use laser
STEREOLITHOGRAPHY (SLA)
 Strength and Weakness

Advantages
• Good surface finish;
• Complex geometry, easily obtained; and
Disadvantages
• Models need support structures that must be removed as a finishing operation;
• Resins are hazardous and need careful handling.
• Building environment is kept below freezing temperature
• Cool water, ejected from the nozzle, is deposited on the
previous layers, and is solidified through convection

• Nozzle and pipe are kept constant at certain

pre-freezing temperature
 Strengths and Weaknesses of
Rapid Freezing Technique

Strengths Weaknesses
• Low operating cost • Require well control
• Good accuracy environment
• Good building speed
• Developed by DTM
• Use bed of powder

• Selectively use CO2 laser to sinter powder

SELECTIVE LASER SINTERING
 Strength and weakness

Advantages
• Parts can often be built without additional support structures; and
• Parts in a range of materials can be obtained directly.
Disadvantages
• Surfaces of the parts are porous, and surface finish can be poor.
• Process machines can take a long time to heat up and cool down.
•
• Developed at MIT
• Manufactured by Z Corp
• Use binding agent instead of laser beam
• Use powder materials
3 DIMENSIONAL PRINTING
 Strength and weakness
Advantages
• Shorter build times when compared to other RP technologies.
• Inexpensive raw materials when compared to other RP technologies.
Disadvantages
• Newly printed parts are fragile.
• Surface finish is relatively poor.
FUSED DEPOSITION MODELING
 Strength and weakness
Advantages
• Parts can be made from a variety of materials.
• Machine can be easily set up and used in an office environment.
Disadvantages
• Support structures are needed.
• Parts have poor strength in the vertical direction.
Applications in various fields

• Rapid manufacturing
• Aerospace and marine
• Automotive industry
• Textile and jewellery
• Electrical and electronic appliances
• Architecture
• Biomedical applications
Applications
 Rapid Response Manufacturing is the recent trend of
manufacturing to reduce the product design and development time.

• Model making, Pattern making and or mould making for

investment casting can be done by Rapid Prototyping Techniques.
• Selection of proper RP method is important.
 References
 Advanced Machining Processes- V.K. Jain
Allied Publishers Pvt. Ltd. (2005)
Advanced Methods of Machining- McGeough J.A.
Chapman and Hall , London,(1988)

 https://en.wikipedia.org/wiki/Rapid_prototyping

https://searcherp.techtarget.com/definition/rapid-prototyping
THANK YOU