VISVESVARAYA TECHNOLOGICAL UNIVERSITY

By
Santosh M Paple
PDM, VTU Belagavi
 In the development of a new product, there is a need to produce a
single prototype, of a designed part or system before allocating large
amounts of capital to new production facilities or assembly lines.

 Consequently, a working prototype is needed for design evaluation

and troubleshooting before a complex product or system is ready to
be produced and marketed.

 The traditional method of fabricating a prototype part is machining,

which can require significant lead times.

 A virtual prototype, which is a computer model of the part design on a

CAD system, may not be adequate for the designer to visualize the
part.
 It certainly is not sufficient to conduct real physical tests on the part,
although it is possible to perform simulated tests by finite element
analysis or other methods.

 Rapid Prototyping (RP) is a family of fabrication methods to make

engineering prototypes in minimum possible lead times based on a
computer-aided design (CAD) model of the item.

 RP technologies, a solid physical part can be created in a relatively

short time

 The designer can therefore visually examine and physically feel the
part and begin to perform tests and experiments to assess its merits
and shortcomings.
 Rapid prototyping serves as an important tool for visualization and

for concept verification.

 With suitable materials, the prototype can be used in subsequent

manufacturing operations to produce the final parts. Sometimes

called direct prototyping, this approach can serve as an important

manufacturing technology.

 Rapid-prototyping operations can be used in some applications to

produce actual tooling for manufacturing operations. Thus, one can

obtain tooling in a matter of a few days.

Rapid-prototyping processes can be classified into three major
groups:
 Subtractive: As the names imply, subtractive processes
involve material removal from a workpiece that is larger than
the final part.
 Virtual processes: Use advanced computer-based
visualization technologies.

 Additive processes: build up a part by adding material

incrementally to produce the part.
The traditional method of fabricating a prototype part is
machining, which can require significant lead times.
This approach requires skilled operators using material removal
by machining and finishing operations one by one-until the
prototype is completed.
To speed the process, subtractive processes increasingly use
computer-based technologies such as the following:
1. Computer-based drafting packages
2. Interpretation Software
3. Manufacturing Software
4. Computer Numerical control
 Virtual prototyping is a software-based
method that uses advanced graphics and
virtual-reality environments to allow
designers to view and examine a part in
detail.

 This technology, also known as

simulation-based design, uses CAD
packages to render a part such that, in a
3-D interactive virtual environment,
designers can observe and evaluate the
part as it is being drawn and developed.
Additive rapid-prototyping operations all build parts in layers,
which are typically 0.1 to 0.5 mm thick and can be thicker for
some systems.
 Additive operations require elaborate software.
 The first step is to obtain a CAD file description of the part.
 The computer then constructs slices of the three-dimensional
part.
 Each slice is analyzed separately, and a set of instructions is
compiled in order to provide the rapid-prototyping machine
with detailed information regarding the manufacture of the
part.
 Rapid-prototyping techniques have made possible much faster product

development times, and they are having a major effect on other

manufacturing processes.

 When appropriate materials are used, rapid-prototyping machinery can

produce blanks for investment casting or similar processes, so that

metallic parts can now be obtained quickly and inexpensively, even for

lot sizes as small as one part.

 Such technologies also can be applied to producing molds for

operations (such as injection molding, sand and shell mold casting, and

even forging), thereby significantly reducing the lead time between

design and manufacture.

1.The high cost of labor and short supply of skilled patternmakers can be
overcome.

2. There is a major reduction in lead time.

3. Hollow designs can be adopted easily so that lightweight castings can

be produced more easily.

4. The integral use of CAD technologies allows the use of modular dies
with base-mold tooling (match plates) and specially fabricated inserts.
This modular technique can further reduce tooling costs.

5. Chill- and cooling-channel placement in molds can be optimized more

easily, leading to reduced cycle times.