Rapid Prototyping / Additive Manufacturing / Rapid Manufacturing

RAPID PROTOTYPING /
ADDITIVE
MANUFACTURING /
RAPID MANUFACTURING
Classification of Manufacturing
Casting (Primary Process) (Zero Process) (3200 B.C. A
copper frog, the oldest known casting in existence, is
cast in Mesopotamia.
3000 BC Earliest castings include the 11 cm high bronze
dancing girl found at Mohen-jo-daro)
Metal Forming Process (Primary Process) (Zero Process)(The
oldest known industrial metal mining and working operation
has been dated to the discovery of
a copper pendant in northern Iraq from about 8,700 BCE)
Classification of Manufacturing
Joining Processes (Positive Process) (Arc welding –
1801)
Powder Metallurgy (Engineers in the 1800s began
utilizing metal powders to create laboratory instruments
with platinum)
Machining Process (Secondary Process) (First lathe –
Rapid Prototyping is Positive process

1751)
Introduction to Rapid Manufacturing
Contents
Additive Manufacturing
Rapid Manufacturing
Functional Prototyping
Rapid Tooling
Indirect and direct Manufacturing
Why Rapid Prototyping?
Examples of Camera, Adjustable chair, Shoe & Car (These products are
not customized)
We do not have customization, we accept what is available.
Camera, Adjustable chair are manufactured for right hand users, not for left
hand users.
Shoes are manufactured with standard sizes. Using the shoes which are not
suitable for your feet leads to knee pain.
Cars are manufactured with standard sizes. Car manufacturers do not
consider the driver height, weight, right hand user or left hand user, male or
female. But customers spend more money on cars.
Challenge - Quality
Why is it not done?
Because the users are not captured so the product is not made.
What is the challenge?
Produce more in terms of batches, but make it more mass customized. In
mass customization manufacturers cannot sacrifice time and cannot
sacrifice the cost. So, we are still supposed to work to the expectation of the
customer both in terms of economy and in terms of time delivery.
Engineers are pushed from mass production to batch production to mass
customized production.
This mass customized production is termed or is redrafted as Rapid
Manufacturing
Rapid Manufacturing
Why rapid manufacturing?
The industrial 3D printer is at the tipping point, about to go
mainstream in a big way. (Earlier the raw material was plastic,
now it is changed into metal.)
Most executives and many engineers do not realize it, but this
technology has moved well beyond prototyping, rapid tooling and
toys.
“Rapid Manufacturing” is creating durable and safe products for

sale to real customers in moderate to large quantities.
What is Rapid Manufacturing?
Engineers try to take the feedback or requirements from the
customer converted it into a digital form; and that digital
form is given directly to the machine the parts are produced
and directly moved towards an application.
Examples of layer by layer – Rainbow cake
Examples of layer by layer - Plywood
Rapid Manufacturing
Form, Fit, Function
Seen here attached to the US Navy's M4A1 machine

Seen here attached to the
gun, an ABS USprototype
Navy's M4A1stock
machine
wasgun, an ABS
tested on(Acrylonitrile
the firing Butadiene Styrene)
prototype stock was tested on the firing range with live ammunition. Prototype built on FDM system
from Stratasysrange with live ammunition. Prototype built on FDM
system from Stratasys.
Rapid manufacturing course content
Major Modules
 Introduction to Rapid Manufacturing
 Product Engineering
 CAD/CAE/CAM and CIM
 Design for modularity
 Reverse Engineering
 Rapid manufacturing processes and technologies
 Rapid manufacturing Digital factory
 Competitiveness in rapid manufacturing
‘Rapid prototyping’ course outcome
Participate in a discussion with your peers, cater the
interview questions and take an examination on Rapid
Manufacturing.
Identifying the tangible and intangible elements of Rapid
Manufacturing
Select a process, tool, material for your product.
Define broadly the level of Rapid Manufacturing systems
from techniques, production lines, to digital facilities for
the entire enterprise.
Classification of Rapid prototyping
LIQUID-BASED
Stereo lithography (SLA)
SOLID-BASED
Fused deposition modeling (FDM)
Laminated object manufacturing (LOM)
POWDER-BASED
3D Printing
Selective laser sintering (SLS)
Direct metal laser sintering (DMLS)
https://www.thingiverse.com/
Additive Manufacturing also called layered
manufacturing.
Additive Manufacturing is a layered based automated fabrication
process for making scale 3 dimensional physical objects directly
from a 3D cad data without using part depending tools. (Rapid
Manufacturing is I would like to build the 3 dimensional objects
from fundamentally 2 dimensional layers. I make layer by layer
by layer, I stitch those layer by layer by layer and make it into a 3
D physical object.)
It was originally called as 3D printing.
Together with the well-established subtractive manufacturing
such as milling or turning and the formability manufacturing such
as casting and forging, Additive Manufacturing provides the third
supporting pillar of the entire manufacturing technology.
Additive Manufacturing
 When the first approaches to Additive Manufacturing entered the
market in 1987, it is very new it was called as Rapid Prototyping or it
was called as Generative Manufacturing.
 Both terms are still in use and in the past years many different names
have been presented and frequently more are added.
 Although each of the name is perfect from the special viewpoint of its
creator many of these causes confusion.
 Often this is one reason why newcomers to the industry in particular
sometimes feel lost in the field of Additive Manufacturing.
 To obtain a brief overview a small selection of the mostly used terms
are structured according to a few families of keywords.
Often used terms include
1. Rapid
Rapid Technology
Rapid Prototyping
Rapid Tooling.
2. Additive
 Additive Manufacturing
Additive Layer Manufacturing
Additive Digital Manufacturing.
3. Layer:
layer based manufacturing
layer oriented manufacturing
layer manufacturing.
4. Digital
digital fabrication
digital mock up.
5. Direct
Direct Manufacturing
Direct Tooling.
6. 3D
3D printing
3D modelling.
The principles of layered based technology
The term Additive Manufacturing like generative manufacturing covers any
imaginable way of adding materials in order to create a 3 dimensional physical
part.
The technical realization of Additive Manufacturing is based solely on layers
and therefore, it is called as layer based technology or layer oriented technology
or even layer technology.
Consequently today the terms Additive Manufacturing, Generative
Manufacturing and layered based technologies are sometimes used
synonymously.
In the future as new additive technologies may become available they will need
to be classified within the current structure of Rapid Manufacturing definition.
2D layer to 3D Part
layer to layer (Example)
Difference between machining and additive
manufacturing
MachiningProcess – Negative process
Rapid manufacturing – Positive process
Additive manufacturing
Additive manufacturing – Economical
Manufacturing is an automated and revolving process developed
from the principle of layer based technology.
It is characterized by a process chain illustrated in the figure.
It starts from a 3D CAD dataset that represents the part to be
produced.
In engineering, the data set is typically obtained by 3D CAD
design or by scanning or other imaging technologies such as
computerized tomography scanning, (CT-Scanning is) also used
for developing the data independent of how it is obtained a 3D
data set is first sliced into layer using a computer and a special
software. (includes)
Process chain of Additive manufacturing
Virtual CAD model using computer
Obtain the contour by slicing the CAD model on the computer

Making of physical layer due to contour information + merging
the physical layer on top of each other

Physical Additive Manufacture part
Additive manufacturing - Process
As a result a set of contour virtual slices with even
thickness is obtained. (Today, this also has changed. You
can have varying slice thickness.)
The data set
 Consisting of the contour data (x-y).
 The layer thickness (dz).
 The layer number (in z direction) of each layer, is
submitted to a machine that executes two elementary
process steps per layer in order to create the part.
First,each layer is proposed is processed according to the given
contour and a layer thickness data.
This can be done in many ways by using different physical
phenomena. The most simple method is to cut the contour from a
prefabricated sheet or foil.
In the second step, each layer is bonded to the preceding layer,
now forming the top layer of the partly finished model
Again, the simplest method is to use a contour foil and glue it on
top of the preceding layer. Layer by layer, the physical model is
growing from the bottom to the top until the final part is obtained.
 These basic steps, called a process chain, are the same for all of the approximately
hundreds of different AM machines available today. The machines differ only by
the way each layer is processed. So, the starting material if it is liquid it you can
use laser, if it is a wire you can use passing through a hot nozzle, if it is a powder
you can glue that powder and by the way adjacent layers are joined to form a part.
 The machines differ only by the way each layer is processed and by the way
adjacent layers are joined to form the part
 As a first conclusion Additive Manufacturing is the manufacturing process:
I. based just on the 3D set, 3-dimensional visual objects called as digital product
model or CAD model
II. Using layers of even thickness contour according to the corresponding cross
section of the product level.
AM therefore, basically is a 2.5 D process does not interfere
with the design process and therefore, can be done at any
stage of the product development. (X & Y is 2D)
That mostly uses proprietary materials thus, forms a strong
linkage between machine process and building material.
This effect will diminish with increasing number of
machines in the market and the rising attraction of third
party material suppliers enter into the market.
Additive manufacturing – Application levels
 Most of the peoples interest in Additive Manufacturing preferably
wanted to know how they can use this new technology and what kind
of new and different products they can develop using it.
 In addition, it is advantageous to use the right term during the
discussion in the product development team.
 Many thinks that each of their different AM processes is exclusively
linked to a certain application in the sense that a certain AM process
can only be used for one or a small range of application while the
other processes is solely suitable for another application.
 This opinion encourages people to study all different process first and
to care about a suitable application afterwards.
In practice identification of the best applicable AM
process starts with the respective application.
Then, special requirements, such as dimension,
resolution, surface quality, tolerances, temperature etc
lead to the suitability of the material and finally, to a
machine capable of handling all these requirements
properly.
In general, different Additive Manufacturing process can
use alternative to solve the same problem.
As can be seen in the illustration AM technology is
characterized by two main application levels
1. Rapid Prototyping and
2. Rapid Manufacturing.
Rapid Prototyping describes all applications that lead to
prototypes, Samples, models, mock-ups, while Rapid
Manufacturing is used when final parts or even products
are made.
Rapid Manufacturing – Direct manufacturing
 The data was obtained from the patient by a
dental imprint and then digitized.
 With the use of the professional dental software
3 shape the dental bridge was designed and
directly manufactured using SLM process.
 After finishing and geometric testing, the
bridge was ready to be place/d in the patients
mouth.
Cobalt – Chromium alloy
 Regarding traditional process, the directly
manufacture bridge was made quicker, with a
perfect fit and a comparable cost.
Rapid Tooling
Rapid tooling, involves all AM procedures that lead to a
final product used as core, cavity or insert for tools, dies
and molds.
Two sub level must be distinguished
 Direct tooling
 Prototype tooling.
Direct tooling is a technical equivalent to direct
manufacturing, but leads to tool inserts, die, mold in
series quality.
Rapid Manufacturing
Rapid Tooling and Manufacturing
 RP processes have been used as a manufacturing step in production
besides demonstration and visualization tool.
 Two basic methodologies:

1. Direct production of engineering metal, ceramic, polymer components
or parts by rapid prototyping - Rapid Manufacturing
2. Production of tooling by rapid prototyping for use in further

manufacturing process.
Rapid Manufacturing
Characteristics
 RP operations can be used to manufacture parts directly. The
component is generated directly to a near-net shape from a
computer file on part geometry.
Rapid Tooling
Characteristics
 An application of RP is rapid tooling - an automatic
fabrication of machine tools. Tooling is one of the most costly
steps in the manufacturing process.
 Tools are often complex and need to be wear resistant for

production. To meet these requirements, molds and dies are
traditionally made by CNC machining, EDM or other
methods.
Rapid Tooling
Characteristics
 Traditional
methods are expensive and time consuming;
making rapid tooling prototyping the desired alternative.
 By using rapid prototyping, tooling and design cost may be

cut by 50% to 70%.
Rapid Tooling
 Rapid prototyping is used in two ways to make tooling:
1. Direct Tooling
- Molds or other tools may be directly fabricated by
RP system
2. Indirect Tooling
◦ RP-generated parts can be used as patterns for
fabricating a mold or tool through so-called
indirect or secondary processes.
Rapid Tooling
 Direct Tooling / Direct Fabrication Processes
 Specialized RP processes have been developed to meet
specific application and material requirements for moulding
and casting.
 These may be forms of basic RP processes, such as SLS, or

may be unique RP methods developed for a specific
application.
Rapid Tooling
 Direct Tooling / Direct Fabrication Processes
 To make metal tooling direct from CAD file through

rapid prototyping process; is the answer to every
production engineers dream.
Rapid Tooling
 Processes
 Rapid tool – A process which uses SLS to sinter poly-

coated steel pellets together to produce metal mould.
 LOM Composite – A method of using ceramic composite

material for Laminated Object Manufacturing.
 Sand Moulding – A rapid prototyping technique that

constructs sand moulds directly from a CAD file.
Rapid Tooling
 Processes
 Laser Engineering Net Shaping (LENS) – A process that

can create metal tools directly from a CAD file.
- This process is capable of using multiple materials, stainless
steel, HSS, tungsten carbide as well as others.
 A laser beam melts the top layer of the part in areas where
material is to be added until the part is complete.
 Unlike sintering, LENS does produce a solid metal part
since the metal was melted.
Rapid Tooling
 Indirect or Secondary Processes
 Although the properties of rapid prototyping materials

continue to improve and expand, their comparatively small
number and a limitless array of applications
 There will always be a need to transfer parts fabricated in a

material used in an additive fabrication process into yet
another material.
 Consequently,numerous material transfer technologies

have been developed.
Rapid Tooling
 Typically a part made by the RP system is used as a pattern

or model in these processes.
 As in the case of the direct fabrication processes discussed

above, there are many secondary processes in various
stages of development.
 However, of the more than two dozen such methods

available or under investigation, just a few are common and
commercially important today.
Contents
•Product and it is characteristics
•Evolution of a product development
•Sequential product development
•Stages in generic product development process
•Design specification in the process
•Conceptual and detailed designing.
Product Development
The product life cycle is a sequence of all the required
activities that a company must perform to develop
manufacture and sell a product.
These activities can include marketing, research,
engineering design, quality assurance, manufacturing and
a whole chain of supplier and vendor
The process also comprises all strategic planning, capital
investment management decision and task necessary to
create a new product.
Product Development
An important part of product development is the engineering
design process, which can be designed as a process of devising a
system component or process to meet the desired requirement.
Engineering design consists of several sequential or parallel
activities that begin with identifying the need and concluding
with a ready to manufacture product.
The prototyping is considered to be the first product completed
in the production process.
It is produced using all manufacturing processes and test
procedures called by the design drawing and specification.
Product Development
The product development is evolving from a sequential
process carried out primarily by engineers to an
integrated process incorporating a cross functional team.
Similar steps are followed in either cases, but there are
accomplished concurrently and with the higher speed in
the integrated process environment.
Product Development
Four logical group of activities can be identified in product
development:
Identifying an opportunity or a demand.
Creating a technical specification for the new product
idea.
Developing the manufacturing process to produce the
new product this is also challenge.
Fabricating the new product
Product Development
Inthe first group market or potential markets are analyzed to
generate customer needs, meaning that the customer will eventually
generate the requirements for the desired product features and
functions.
The market information is usually compiled by marketing
specialists who translate it into a set of product features or product
descriptions that are intended to satisfy a certain target customer
base.
The process also comprises all strategic planning, capital investment
management decision and task necessary to create a new product.
So, all these things are part of product life cycle
Product Development (Pencil,Dosa)
In the first group market or potential markets are analyzed to generate
customer needs, meaning that the customer will eventually generate
the requirements for the desired product features and functions.
The market information is usually compiled by marketing specialists
who translate it into a set of product features or product descriptions
that are intended to satisfy a certain target customer base.
This process also includes analyzing other products that meets the
target needs offered by competitors to find their point of both strength
and weakness, so that effort can be made to overcome weaknesses and
improve the desired feature.
Product Development
The price range that also has to be estimated at this point by
analyzing the pricing of a similar product.
This in addition to a value of desired profit margin will set
the criteria for the economical feasibility of the new product.
The data are translated into cost and quality specification.
The next step is to formulate the product into a concept based
on the product features set identified by marketing in the
previous step that is a first version of how the product will
look and perform is created
Product Development
Using a initial concept vision the design process proceeds to a
design and test the product until a preliminary design is
completed.
Then a prototype can be created and tested to make sure that the
product is functioning as it should.
The prototype is considered as a first finish product in the sense
that it must be produced using all manufacturing processes, that
the actual product will go through prototyping testing. Thus the
design will be redefined and a new prototype is produced.
This will continue until no more modifications are required
The next step is to finalize the product documentation
and then the manufacturing process development may be
initiated.
The manufacturing process must be created so that the
product can be produced in the production facility.
After the product design and development of manufacturing
process are completed. The business for producing and
shipping of the product begins.
The raw materials can be purchased and the production
facility can get into operations.
During the first two production period some problem may
arise as a result of technical production problem which will
lead to design modifications to resolve these new problems
and reach the expected production rate with the intended
quality.
Definition of product
In marketing a product is anything that can be offered to
a market that might satisfy a want or a need.
In business, Products are called as merchandise
In manufacturing products are brought as raw material
and sold as finished goods.
A service is another common product type.
Product Design
Product design deals with conversion of dreams into reality; in
order to fulfill human needs.
A designer produces the prototype by the way the designer
means it is not an artist designer means you have a customer
asking the customer their need.
Responsibility of a designer if producer believes that sufficient
number of customers will be satisfied then mass production
may be taken up by the production cell.
If there is an error in the design he has to reiterate, designer
has to reiterate.
key factor for to a successful product
Distinctiveness
Distinctiveness for successful product a key factor for to
a successful product is distinctiveness, provide excellent
value for the money spent and enhanced quality
perceived is very important
Customer focuses and market orientation.
Develop and intensive understanding of the trait of the
market
recognize the competition
Sharp and early product production
An outline of the concept and the benefit to be provided
A list of product attributes and features; attributes, features
are different, attributes good bad feature.
Execution of activity
Better job across the activity identifies under homework
and market orientation.
The team should not skip market studies and undertake
trial sells so market study has to be done
The organizational behavior this is one of the key factors
for a successful product the team comprises members of
all basic functions
research and development
engineering design
production quality and
sale.
Successful Product Development
Cost : The cost of both producing and developing.
value : Quality of the product
time : For assessing market needs to product sales
technology know how: The actual procedure to follow.
Product characteristics
The major product characteristics are
Functional or performance aspect.
Operational or ease to use aspect.
Ease of maintenance.
Aesthetic and appearance.
Customer so price to customer or value added aspects.
Introduction
Modular design is made with an approach that subdivides
a system into smaller parts called modules or skids, that
can be independently created and then used in different
systems.
A modular system can be characterized by functionally
partitioning into
 Discrete, scalable, reusable modules.
 Rigorous use of well defined modular interface.
 Making use of industrial standards for interface.
Design for modularity
Design for modularity, can be advantageous in many
ways.
Reduction in cost
Flexibility in design right
Augmentation
Design for manufacturing
Before discussing design for modularity the concept of
design for manufacturing and design for assembly has to
be understood.
 Design for manufacturing,
 Design for assembly and
 Design for modularity.
Definition for design for manufacturing is a design
technique for manufacturing ease of an assortment of
parts that would constitute the final product after
assembly.
Design for manufacturing focuses on minimizing the
complexity involving the manufacturing was operations
as well as reducing the overall part production cost.
Design for manufacturing is also the process of proactively designing the
products too.
 Optimize all the manufacturing functions like
 fabrication,
 assembly,
 testing,
 procurement,
 shipping,
 delivery,
 service, and
 repair.
Assure the best in
 cost,
 quality,
 reliability,
 regulatory
 compliance,
 safety,
 time to market and
 customer satisfaction.(The earlier one was functions of
manufacturing.)
Design review
Design review the purpose of design review is to provide
systematic and thorough product process analysis.
The formal record of that analysis
Feedback to the design team for product and process
improvement is also given out of this design review.
Some commonly associated problems with the
implementation of the design review processes are.
 unevenly matched skills and knowledge among the
design reviewer team.
 Lack of communication
 No time to make design review based changes so this is a
problem.
 Lack of design review experience.
Stereolithography
Stereolithography
Stereolithography (SLA or SL; also known
as stereolithography apparatus, optical
fabrication, photo-solidification, or resin printing)
is a form of 3D printing technology used for
creating models, prototypes, patterns, and
production parts in a layer by layer fashion
using photochemical processes by which light
causes chemical monomers and oligomers to cross-
link together to form polymers.
Stereolithography is an additive manufacturing
process that, in its most common form, works by
focusing an ultraviolet (UV) laser on to a vat
of photopolymer resin.
UV range: 150nm to 300nm.
Oligomers are low molecular weight polymers
comprising a small number of repeat units whose
physical properties are significantly dependent on
the length of the chain.
Stereolithography
Curing process
 Curing is a chemical process employed in polymer chemistry and process engineering that
produces the toughening or hardening of a polymer material by cross-linking of polymer
chains.
Stereolithography
A base support is positioned on an elevator platform and immersed in a tank of liquid
photosensitive monomer, with only a thin liquid film above it.
 A UV laser locally cross-links the monomer on the thin liquid film above the structure support base.
 The elevator plate is lowered by a small prescribed step, exposing a fresh layer of liquid monomer,
and the process is repeated
 At the end of the job, the whole part is cured and excess resin and support structures are removed
(Waves)
Stereolithography
 Solidification of the monomer can occur in two different
modalities:
 Free surface mode: Solidification occurs at the resin/air
interface. In this mode, care must be taken to avoid waves
or a slant of the liquid surface, which would compromise
the final dimensional resolution. The elevator moves down
at each step (top-down build).
 Fixed surface mode: The resin is stored in a container with

a transparent window plate for exposure, and solidification
occurs at the stable window/resin interface. In this mode,
the elevator moves up at each step (bottom-up build).
Stereolithography
Two fundamental process variations exist:
 Scanning stereolithography. The laser beam is rastered onto

the surface. Parts are constructed in a point-by-point and
line by-line fashion, with the sliced shapes written directly
from a computerized design of the cross-sectional shapes.
 Projection stereolithography. A parallel fabrication process
in which all the voxels in a layer are exposed at the same
time; the topology to be printed on each layer is defined by
2D shapes (masks). These 2D shapes are either a set of real
photomasks or digital masks defined on a DLP projector
Stereolithography
Curing process
 Curing is a chemical process employed in polymer chemistry and process engineering that
produces the toughening or hardening of a polymer material by cross-linking of polymer
chains.
Stereolithography
A base support is positioned on an elevator platform and immersed in a tank of liquid
photosensitive monomer, with only a thin liquid film above it.
 A UV laser locally cross-links the monomer on the thin liquid film above the structure support base.
 The elevator plate is lowered by a small prescribed step, exposing a fresh layer of liquid monomer,
and the process is repeated
 At the end of the job, the whole part is cured and excess resin and support structures are removed
(Waves)
Photopolymerization
Photopolymerization makes use of a liquid, radiation
crucible resin or a photopolymer as their primary
material. A photopolymer or a light activated resin is a
polymer that changes it is property when exposed to
light, often in the presence of UV light or visible region
of a electromagnetic spectrum.
Photopolymerization
Most photopolymers react to radiation in the UV range of
wavelengths, but some visible light systems are also used.
So, predominantly it will be UV based so, you take a UV
light. So, basically you can take a UV lamp or you can take
a UV laser for curing it. We prefer UV laser because you
can have fine resolutions in the developed material. Upon
irradiation, these materials undergo a chemical reaction to
become a solid. This reaction is called as
photopolymerization and is typically complex involving
many chemical participants.
Photopolymerization
Photopolymerization
So, this is a liquid polymer, this is you can see blue small
dots are called as monomers and along with the monomers
you have this violet one are called as oligomers and then
we have photoinitiators which are green and when the UV
light hits on it you can see these mers are trying to form a
network with oligomer. They are trying to form a oligomer
and the photoinitiator are used to start the reaction and
form this bond between them. So, because of the bond
forming this is the bond this tries to make it into a solid.
Photopolymerization
Photo curable resins are also used in dentistry such as for
sealing the top surface of the teeth to fill in deep grooves
and prevent cavities. In these applications, coatings are
cured by radiation that blankets the resin without the
need of patterning either the material or the radiation.
This changed with the introduction of stereolithography.
Photopolymerization
Stereolithography, lithography is light for making 2D
structures. If want to make a 3D structure. So, I call this
process as stereolithography. Lithography means you
have a light where in which this light is exposed on top of
a mask. So, light exposed on top of a mask. This is a
mask and then you have some material, this material is
getting the mask transferred, you have a photopolymer.
So, because of the light exposure, you get this photo resin
on curing it tries to create this structure
Photopolymerization
The various types of radiations maybe used to cure commercial
photopolymers including gamma rays, X-ray, electron beam,
UV and in some cases visible light.
In SL system UV and visible light radiations are used most
commonly.
In the microelectronic industry photo mask material are often
photopolymers and are relatively irradiated using far UV and
electron beam.
In contrast the field of dentistry uses a visible light
predominantly, this is used for curing and making the caps.
Photopolymerization - configurations
vector scan or point wise approaches typically of
commercial SL machines
Mask projection or layer wise approach that irradiates
entire layer at one time.
Two-photon approach that are essentially high resolution
point by point approach.
Photopolymerization
Photopolymerization
This laser predominantly is UV laser. So, that it can go cure
the liquid polymer passes through optics, so this optics is for
beam adjustment in terms of shape, in terms of focus
diameter. So, this optics place a very important role.
The thing is when we wanted to make an object which is
slightly large and if you want to move this table in a high
speed maybe 100 meters per minute or something like that.
So, then what happens the ball screw mechanism, what is
used or the belt drive mechanism what is used, is not of high
repeatable or it gives you a poor repeatability.
Photopolymerization
So, in order to avoid this what we do is, nowadays we try to
go for a scanning galvanometer, this galvanometer tries to
sweep in one direction; it is pivoted here in one direction.
So, it tries to hit at layer of polymer and tries to cure in the x
and y plane. So, it hits and moves on the x and y plane of a
single layer. So, this once a single layer is cured the table is
move down by a required layer thickness or whatever you
have assigned layer thickness it sinks down. So, then once
the object which is cured sinks down now the fresh
photopolymer face on top of i
Two photo approach
Two photo approach
Two-photon approach, scanning laser beam are needed,
while the mask projection approach utilizes a large
radiation beam that is patterned by another device, in this
case it is a digital micromirror device. Which is nothing,
but DMD, DMD stands for digital micromirror device.
In the Two-photon case photopolymerization occurs at
the interaction of 2 scanning laser beams, although other
configuration uses a single laser at different photoinitiator
chemistry.
Two photo approach
Another distinction is the need to recoat or apply a new
layer of resin in the vector scan and mask projection
approach while in the 2 photon approach, the path is
fabricated below the resin surface making recoating
unnecessary.
Photopolymerization materials
These are used as photo resists in the microelectronic industry.
This application has a major impact on the development of
epoxy based photopolymers. The photoresists are essentially
one layer stereolithography, but with critical requirements on
accuracy and feature resolution.
The various types of radiation maybe used to cure commercial
photopolymers include gamma ray which I discussed earlier, X
ray, electron beam, UV and in some cases visible light,
although UV and electron beam are most commonly used.
In rapid manufacturing many of these radiation sources
have been utilized in research. However, only UV and
visible light systems are effectively used in real time
product in SL system for example, UV radiation is used
although in principle other types could be also used.
In SLA 250 from 3 D system, this is a machine which is supplied by
3d system a helium - cadmium laser, helium- cadmium laser with a
wavelength of 325 nanometer which is in UV is used. In contrast, solid
state laser used in the other SL models are Nd YVO4 laser is also used.
In mask projection DMD digital micromirror device based system
mask projection system UV and visible light radiations are used.
Thermoplastic polymers that are typically injections molded have a
linear or a branched molecular structure, that allows them to melts and
resolidify repeatedly.
In contrast SL photopolymers are cross linked thermo sets, and as a
result do not melt and exhibit much less creep and stress relaxation.
UV curable photopolymers
The epoxy resin produced more accurate harder and stronger
parts than the acrylate parts so poly epoxide composition.
While the polymerization of acrylate composition leads to 5
to 20 percent shrinkage, the ring open polymerization of
epoxy composition only lead to the shrinkage of 1 to 2
percent then people started getting away from this acrylate
based photopolymerization to epoxy composition
photopolymerization. This low level of shrinkage associated
with epoxy chemistry contributes to excellent adhesion and
reduced tendency for flexible substrates to curl during curing.
The overview of photo polymer chemistry the SL
stereolithography photopolymer are composed of several
types of ingredients, photo initiator, reactive diluents,
flexibilizer, stabilizer, liquid monomer.
Broadly speaking when UV radiation impinges on SL resin
the photoinitiator undergo a chemical transformation and
becomes reactive with a liquid monomer. So, this fellow will
absorb the UV and start giving energy or start initiating the
bond between the different mers. The reactive photoinitiator
reacts with the monomer molecules to start a polymer chain
Two main types of photopolymer chemistry are
commercially evident, free radical photopolymerization
which is nothing but an acrylates, cation
photopolymerization which is epoxy and vinyl ether. The
symbol C and H denotes carbon and hydrogen atoms
respectively, while R denotes a molecular group which
typically consists of one or more vinyl groups. A vinyl
group is a molecular structure with a carbon - carbon double
bond, in this vinyl group in the R structure that enables
photopolymers to become cross linked
The overview of photopolymer chemistry, free - radical
photopolymerization was the first type that can be commercially
developed. Since SL resins were acrylate the acrylates form long
polymer chain once the photoinitiators becomes ‘reactive’ building
the molecular linearly by adding monomer segments. Cross-
linking typically happens after the polymer chain grows enough so
that they become close to each other. Acrylate photopolymer
exhibits high photo speed, but have a number of disadvantages
including significant shrinkage and the tendency to warp and curl.
As a result they are rarely used now without epoxy or other
photopolymer elements.
When reacted, these rings open resulting in sites for other
chemical bonds. Ring opening is known as impart minimal
volume change on reaction because the number and the type
of chemical bonds are essentially identical before and after
reaction. This is a very important point number and the
types of chemical bonds are essentially identical before and
after reaction. As a result epoxy SL resins typically have
much smaller shrinkage and much less tendency to warp
and curl almost all commercial available SL resins have
significant amount of epoxies.
Polymerization of SL monomers is an exothermic
reaction, please understand exothermic heat is generated
during the curing process with heat of reaction around 85
kilo joule mole for an example acrylic monomer does.
Despite high heat of reaction a catalyst is necessary to
initiate the reaction. So, temperature alone does not
initiate we need one more catalyst to initiate such that the
epoxy type SL resins get cured and they form a solid
object.
The resin formulation and reaction mechanism the basic
raw material such as
polyoxyl, epoxides and acrylic acid and other esters,
diisocyanates etc..
are used to produce monomers and oligomers used for
the radiation curing.
Most of the monomers are multifunctional monomers
MFM or polyol poly acrylates which gives a cross
linking polymerization
The main chemical families of oligomer are poly ester
acrylate PEA, epoxy acrylate EA, urethane acrylates UA
and amino acrylates used as photo accelerators in the photo
initiator systems and cycloaliphatic epoxies. Resin supplier
creates ready to use formulation by mixing the oligomers
and monomers with the photoinitiators, as well as the other
materials to affect reaction rate and part properties. In
practice photosensitizers are often used in the combination
with the photoinitiator to shift the absorption towards the
longer wavelength
Stereolithography
Maximum build size 1500mm x 750mm

x 550mm
Resolution in (x,y) Spot Dependent
Resolution in z 0.004”
Speed Medium
Cost High
Available materials Thermoset
polymers:
photosensitive
resins
MEMS & NEMS
Micro-Electro-Mechanical Systems, or MEMS, is a
technology that in its most general form can be defined as
miniaturized mechanical and electro-mechanical
elements (i.e., devices and structures) that are made using
the techniques of microfabrication.
Nanoelectromechanical systems (NEMS) are a class of
devices integrating electrical and mechanical
functionality on the nanoscales
34
Stereolithography
(SLA)
APPLICATION TO MEMS AND NEMS
• The application of rapid prototyping (RP)

techniques to MEMS and NEMS requires
higher accuracy than what is normally
achievable with commercial RP equipment.
• Laminated object manufacturing (LOM),
fused deposition modeling (FDM), and
selective laser sintering (SLS) all must be
excluded as microfabrication candidates on
that basis.
• Only stereolithography has the potential to
achieve the fabrication tolerances
required to qualify as a MEMS or NEMS
tool.
• Latest enhancements that have made it an
attractive option are high-resolution micro-
and nanofabrication methods.
EPFL, Lausanne, Switzerland
35
Stereolithography
(SLA) MICROSTEREOLITHOGRAPHY
• Microstereolithography, derived from conventional

stereolithography, was introduced by Ikuta in 1993.
• Whereas in conventional stereolithography the laser

spot size and layer thickness are both in the 100-μm
range, in microstereolithography a UV laser beam is
focused to a 1–2-μm spot size to solidify material in
a thin layer of 1–10 μm.
• The monomers used in RP and micro-

stereolithography are both UV-curable systems, but
the viscosity in the latter case is much lower,
because high surface tension hinders both efficient
crevice filling and flat surface formation at the
microscale.
www.miicraft.com
• In microstereolithography the solidified polymer is

light enough so that it does not require a support as
is required for the heavier pieces made in RP.
36
Stereolithography
(SLA) TWO-PHOTON LITHOGRAPHY
• Two-photon provides a further

enhancement
lithography of the SLA resolution.
• Special initiator molecules in the monomer only

start the polymerization reactions if activated by
two photons simultaneously. The laser intensity
field can be tuned so that this event only happens
in a very small region near the focus. The result is
extremely local polymerization, with resolutions in
the tens of nanometers range.
• Two-photon polymerization can occur everywhere

in the monomer bath, as opposed to only at the top
layer, simplifying the hardware requirements
considerably.
www.laser-zentrum-hannover.de
37
Current materials in Additive

Manufacturing
Materials in AM today stereo lithography (SLA)
- Thermoplastics (FDM, SLS) Fused deposition modeling (FDM)
- Thermosets (SLA) Laminated object manufacturing (LOM)
- Powder based composites (3DP)
3D Printing
- Metals (EBM, SLS)
- Sealant tapes, paper (LOM) Selective laser sintering (SLS)
- Starch and sugar (3DP) Direct metal laser sintering (DMLS)
• Functional/structural parts
▫ FDM (ABS and Nylon)
▫ SLS (thermoplastics, metals)
▫ EBM (high strength alloys, Ti, stainless steel, CoCr)
• Non-functional/structural parts
▫ SLA (resins): smoothest surface, good for casting
▫ LOM (paper), 3D Printing (plaster, sand): marketing and concept prototypes, sand casting molds
• As new materials are introduced, more functional components will be manufactured Importantly
AM is one of the best approaches for complex architected materials.
38
Challenges in AM materials properties

predictions
• Most AM processes introduce anisotropy in mechanical properties (z different from x,y)
• Local differences in laser/EB power (e.g., perimeter vs center) introduce heterogeneity in
mechanical properties
• Laser fluctuations might result in embedded defects that are difficult to identify
• All existing machines are open-loop: temperature sensors have been introduced in some
processes, but the readings are not used to optimize the processing parameters on the fly.
Anisotropy is the property of substances to exhibit variations in physical properties

along different molecular axes.
PARAMETERS
INVOLVED
Laser power laser power is found to be approximately proportional to the curing degree of the prototype. When
laser power is increased, the curing degree will be increased. This is due to the fact that, by using a high-power
laser, the resin is exposed to high-intensity UV light which leads more cross-linking. At the same time, the depth
and width of the laser-scanned line increase, thus, improving the curing degree of the prototypes.
Layer pitch. Layer pitch was found to have a reverse relationship with the curing degree. For a high layer pitch,
the curing degree will be low and vice versa. This is because the use of a low layer pitch will result is an
increase in overlaps between adjacent layers and decrease in the amount of uncured resin.
Scan pitch. Scan pitch was found to have a similar relationship as the layer pitch. When a large value of scan
pitch is used, the uncured resin will be more, and thus, the curing degree will be lower.
Scanning speed. The scanning speed used affects the curing degree in the laser-curing process. When the laser
scan is fast, the exposure energy in a unit area is less; thus, the curing degree will be low.
Laser stability. Fluctuations in the laser power will lead to different laser exposures, and thus, affect the curing
degree of the prototype.
Absorption rate of the materials. Resins used in the SL process are photo-sensitive. When the wavelength of
the radiation used is suitable for the resin, or the energy distribution is concentrative, the absorption rate will be
high, resulting in large curing degree.
Environment
Some lasers work at very high temperatures and require water to be used to help cool it down (Phillips).
This has a negative impact on the environment as large amounts of water are wasted every year to be
used as a coolant for these lasers (Phillips).
Thermophysical properties
This article reports a systematic study on the effect of laser system parameters and thermo-
physical properties of substrate materials on laser micromachining.
Optical properties
The absorption coefficient describes the intensity attenuation of the light passing through a material.
Absorption index. A measure of the attenuation caused by absorption of energy per unit of distance
that occurs in an electromagnetic wave of given wavelength propagating in a material medium of
given refractive index.
Refractive index: the ratio of the velocity of light in a vacuum to its velocity in a specified medium.
Stereolithography (SLA)
Layer thickness (Lt): This is the specified thickness that
the model is sliced in the z direction.
Orientation (O): This is the position in which the part is
built.
Post curing time (Pc): This is the time for which the
prototype is placed in a UV oven for complete
solidification
DEFEC
TS
Density Problem
• Scan speed has a significant effect on density .
• At sufficiently low scan speeds, the relative density is almost
independent of the layer thickness for the selected range of the
layer thickness, and a maximum of 99% relative density is
achievable.
• At higher scan speed values, a higher layer thickness results in
less density.
Residual Stress
• Due to localized heating, complex thermal and phase
transformation stresses are generated during the process.
• In addition, frequent thermal expansion and contraction of the
previously solidified layers during the process generates
considerable thermal stresses and stress gradients that can
exceed the yield strength of the material.
• Residual stresses can lead to part distortion, initiate fracture,
and unwanted decrease in strength.
Surface finish
• Parts often require post‐processing operations such
as surface machining, polishing and shot peening to
attain final part surface finish.
• Surface roughness is heavily dependent on laser
processing parameters.
Some measures to reduce distortions
Use high exposure and slow scan speed such that
polymerization is essentially complete under the laser spot.
Use resin with a faster rate of polymerization
Decrease laser power to decrease scan speed for a given
exposure.
Use low-shrinkage resin
Increase layer thickness to increase the strength
Desirable features of SL resin
Improved Impact resistance (less brittleness)
Greater Flexibility
Improved photospeed
Increased Strength
Better overall part accuracy
Electrical conductivity
High temperature resistance
Solvent resistance
Stereolithography (SLA)
Application Range
◦ MEMS/NEMS
◦ Parts used for functional tests
◦ Manufacturing of medical models
◦ Form –fit functions for assembly tests
Advantages
◦ Possibility of manufacturing parts which are impossible to be produced conventionally in a single process
◦ Can be fully atomized and no supervision is required.
◦ High Resolution
◦ No geometric limitations
Disadvantages
◦ Necessity to have a support structure
◦ Require labor for post processing and cleaning
Fused Deposition Modeling (FDM)
The technology was first developed by Scott Cramp in
1988 and the patent was awarded in the U.S. in 1992.
FDM uses the extrusion process to build 3D models.
Stratasys introduced its first rapid prototyping machine,
the 3D modeler in early 1992 and started shipping the
units later that year.
12
Fused Deposition Modeling
(FDM) Current market leaders
The fused deposition modeling (FDM) technology - Stratasys, Inc.
was developed by S. Scott Crump in the late 1980s
and was commercialized in 1990. The double
material approach was developed by Stratasys in
1999.
"Ribbon Tetrus" (Carlo Séquin)
www.nybro.com.au
Stratasys Dimension SST 1200
Courtesy, Dr. Robin Richards,

University College London, UK
Models Fused Deposition Modeling (FDM)
The company’s rapid prototyping systems can be broadly
classified into two categories,
 1. The FDM series and 2. the concept modeler.
 1. The FDM series include models like FDM 3000,
FDM Maxum and FDM Titan.
 The concept modeler series includes models like
Dimension and Prodigy Plus.
Specifications of FDM series
Models FDM 3000 FDM Maxum FDM Titan
Technology FDM
Build size, mm (in) Parts up to Parts up to Parts up to
254 x 254 x 406 600 x 500 x 600 355 x 406 x 406
(10 x 10 x 16) (23 x 19.7 x 23) (14 x 16 x 16)
Accuracy, mm (in) ± 0.127 Up to 127 mm (5 in):
(± 0.005) ± 0.127 (± 0.005)
Greater than 127 mm (5 in)
± 0.038 mm/mm (± 0.0015 in/in)
Layer road width, mm (in) 0.250 to 0.965 (0.010 to 0.038) 0.305 to 0.965 (0.012 to 0.038) Not available
Layer thickness, mm (in) 0.178 to 0.356 (0.007 to 0.014) 0.178 to 0.356 (0.007 to 0.014) 0.25 (0.010)
Support structures Automatically generated with Automatically generated with Insight software; WaterWorks soluble support
SupportWorks software; system
WaterWorks or Break-Away
Support System (BASS)
Size, w x h x d, mm (in) 660 x 1067 x 914 2235 x 1981 x 1118 1270 x 1981 x 876
(26 ´ 42 ´ 36) (88 x 78 x 44) (50 x 78 x 34.5)
Weight, kg (lbs) 160 (350) 1134 (2500) 726 (1600)
Power requirements 208–240 VAC, 208–240 VAC, 230 V, 50/60 Hz,
50/60 Hz, 10 A 50/60 Hz, 32 A 3 phase, 16 A/phase
single phase (min. 50 A dedicated (min. 20 A dedicated service)
service)
Modeling materials ABS (White), ABSi, Investment ABS (white) ABS, Polycarbonate, Polyphenyl-sulfone
Casting Wax, Elastomer, (ABS -
Acrylonitrile Butadiene Styrene)
Software QuickSlice® and Support-Works TM Insight Insight
Specifications of Stratasys’ concept modelers (Courtesy
Stratasys Inc.)
Model
Dimension Prodigy Plus
Technology 3D printing base on FDM FDM
Build size, mm (in) 305 x 203 x 203 (12 x 8 x 8) 203 x 203 x 305 (8 x 8 x 12)
Accuracy, mm (in) ± 0.127 (± 0.005) ± 0.127 (± 0.005)
Layer thickness mm (in) “Standard” — 0.245 (0.010) User selectable:

“Draft” — 0.33 mm (0.013) “Fine” — 0.178 mm (0.007)
“Standard” — 0.245 (0.010)
“Draft” — 0.33 mm (0.013)
Automatic operation Easy to use CatalystTM software imports STL files and CatalystTM software automatically imports and slices STL files,
automatically slices the model, creates any orients the part, generates soluble support structures
necessary support structures and generates build files (if necessary), and creates the deposition path to build parts
Size, w x d x h, mm (in) 914 x 686 x 1041 864 x 686 x 1041

(36 x 27 x 41) (34 x 27 x 41)
Weight, kg (lbs) 136 (300 ) 128 (282)
Power requirements 220–240 VAC, 50/60 Hz, 110–120 VAC, 60 Hz,
6 A or 110–120 VAC, 15 A max. or 220–240 VAC,
60 Hz, 12 A 50/60 Hz, 7 A max
Materials ABS plastic in white (standard), blue, yellow, black, red or green. Custom colors available
Material supply One autoload cartridge with 950 cu. cm. (58 cu. in.) ABS One autoload cartridge with 950 cu. cm. (58 cu. in.) ABS
material and one autoload cartridge with material and one autoload cartridge with
950 cu. cm. (58 cu. in.) support material 950 cu. cm. (58 cu. in.) soluble support material
11
Fused Deposition Modeling (FDM)

1. A spool of themoplastic wire (typically
acrylonitrile butadiene styrene (ABS)) with
a 0.012 in (300 μm) diameter is
continuously supplied to a nozzle
2. The nozzle heats up the wire and extrudes

a hot, viscos strand (like squeezing
toothpaste of of a tube).
3. A computer controls the nozzle movement

along the x- and y-axes, and each cross-
section of the prototype is produced by
melting the plastic wire that solidifies on
cooling.
4. In the newest models, a second nozzle

carries a support wax that can easily be
removed afterward, allowing construction
of more complex parts. The most common
support material is marketed by Stratasys
under the name WaterWorks
Process
 In this patented process, a geometric model of a conceptual design is
created on a CAD software which uses IGES or STL formatted files
 It can then imported into the workstation where it is processed through
the QuickSlice® and SupportWork propriety software before loading to
FDM 3000 or similar systems
 For FDM Maxum and Titan, a newer software known as Insight is used
 Within this software, the CAD file is sliced into horizontal layers after
the part is oriented for the optimum build position, and any necessary
support structures are automatically detected and generated.
 The slice thickness can be set manually to anywhere between 0.172 to
0.356 mm
Process
Tool paths of the build process are then generated which are
downloaded to the FDM machine.
The modeling material is in spools — very much like a
fishing line. The filament on the spools is fed into an
extrusion head and heated to a semi-liquid state.
The semi-liquid material is extruded through the head and
then deposited in ultra thin layers from the FDM head, one
layer at a time. Since the air surrounding the head is
maintained at a temperature below the materials’ melting
point, the exiting material quickly solidifies.
Process
Moving on the X–Y plane, the head follows the tool path
generated by QuickSlice® or Insight generating the
desired layer. When the layer is completed, the head
moves on to create the next layer.
The horizontal width of the extruded material can vary
between 0.250 to 0.965 mm depending on model. This
feature, called “road width”, can vary from slice to slice.
Fused Deposition Modeling (FDM)-
Principle
The principle of the FDM is based on surface chemistry, thermal

energy, and layer manufacturing technology. The material in
filament (spool) form is melted in a specially designed head,
which extrudes on the model. As it is extruded, it is cooled and
thus solidifies to form the model. The model is built layer by
layer, like the other RP systems. Parameters which affect
performance and functionalities of the system are material
column strength, material flexural modulus, material viscosity,
positioning accuracy, road widths, deposition speed, volumetric
flow rate, tip diameter, envelope temperature and part geometry.
Software
 Quickslice® and SupportWorks preprocessing software are used to
run with the systems. However, newer systems like the FDM
Maxum and Titan use an improved software, Insight. The newer
software increases building speed, improves efficiency and is easier
to use than its previous QuickSlice® software. Although both
Maxum and Titan have the same achievable accuracy, they differ
from each other in terms of build volume, layer thickness and their
physical size and weight. An advantageous point for selecting Titan
over Maxum is that the former allows users to have a wider
selection of materials (ABS, Polycarbonate and Polyphenylsulfone),
whereas the latter can only build models using ABS.
Advantages
 Fabrication of functional parts. FDM process is able to fabricate
prototypes with materials that are similar to that of the actual
molded product. With ABS, it is able to fabricate fully functional
parts that have 85% of the strength of the actual molded part.
This is especially useful in developing products that require quick
prototypes for functional testing.
 Minimal wastage. The FDM process build parts directly by
extruding semi-liquid melt onto the model. Thus only those
material needed to build the part and its support are needed, and
material wastages are kept to a minimum. There is also little need
for cleaning up the model after it has been built.
Advantages
 Ease of support removal. With the use of Break Away Support
System (BASS) and WaterWorks Soluble Support System, support
structures generated during the FDM building process can be easily
broken off or simply washed away. This makes it very convenient
for users to get to their prototypes very quickly and there is very
little or no post-processing necessary.
 Ease of material change. Build materials, supplied in spool form
(or cartridge form in the case of the Dimension or Prodigy Plus),
are easy to handle and can be changed readily when the materials in
the system are running low. This keeps the operation of the machine
simple and the maintenance relatively easy.
Disadvantages
 Restricted accuracy. Parts built with the FDM process usually have restricted accuracy
due to the shape of the material used, i.e., the filament form. Typically, the filament used
has a diameter of 1.27 mm and this tends to set a limit on how accurately the part can be
built.
 Slow process. The building process is slow, as the whole cross- sectional area needs to be
filled with building materials. Building speed is restricted by the extrusion rate or the flow
rate of the build material from the extrusion head. As the build material used are plastics
and their viscosities are relatively high, the build process cannot be easily speeded up.
 Unpredictable shrinkage. As the FDM process extrudes the build material from its
extrusion head and cools them rapidly on deposition, stresses induced by such rapid
cooling invariably are introduced into the model. As such, shrinkages and distortions
caused to the model built are a common occurrence and are usually difficult to predict,
though with experience, users may be able to compensate for these by adjusting the
process parameters of the machine.
Applications
Models for conceptualization and presentation. Models can be
marked, sanded, painted and drilled and thus can be finished to
be almost like the actual product.
Prototypes for design, analysis and functional testing. The
system can produce a fully functional prototype in ABS. The
resulting ABS parts have 85% of the strength of the actual
molded part. Thus actual testing can be carried out, especially
with consumer products.
Patterns and masters for tooling. Models can be used as
patterns for investment casting, sand casting and molding.
13
FDM process
parameters
14
(FDM)
KEY METRICS ADVANTAGES
Maximum build size 20” x 20” x 20” • Economical (inexpensive materials)

• Enables multiple colors
Resolution in (x,y) +/- (0.002” - 0.005”) • Easy to build DIY kits (one of the most
Resolution in z +/- (0.002” - 0.01”) common technologies for home 3D
printing)
Speed Slow • A wide range of materials possible by
Cost Medium loading the polymer
Available materials Thermoplastics

(ABS, PC,
ULTEM…)
KEY APPLICATION AREAS

• Conceptual Models www.redeyeondemand.com
• Engineering Models
• Functional Testing Prototypes DISADVANTAGES
• Materials suite currently limited to
thermoplastics (may be resolved by loading)
15
(FDM)Do it Yourself FDM rapid prototyping systems

FAB@Home RepRap
• First multi-material printer available to the public
• Open-source system
• Open-source system
• Founded in 2005 by Dr. A. Bowyer at the University of
• Project goal: open-source mass-collaboration Bath (UK)
developing personal fabrication technology aimed at
bringing personal fabrication to your home (project • Project goal: Deliver a 3D printer that can print itself!
started by H. Lipson and E. Malone at Cornell in 2006). • 1st machine in 2007 (Darwin)
• Popular Mechanics Breakthrough Award 2007 • Replication achieved in 2008
16
(FDM)Do it Yourself FDM rapid prototyping systems
Cubify Cube
• Commercially available fully built for $1,200
• Resolution 0.2mm
• 16 colors
• Prints in ABS and PLA
• Awarded 2012 Popular Mechanics Breakthrough Award
Multiple choice questions
1. What is Rapid Prototyping?.
Process for making a final product
Process of delivering final product to the customer
Process for rapidly creating a system or part representation before final release or commercialization
None of these
2. Rapid Manufacturing is creating durable and safe products for sale to real customers in moderate to large
quantities
True
False
3. Additive manufacturing is generally a ________ process.

a) 1D b) 2D c) 2.5D d) 3D
4. Solid imaging or concept modelling defines a family of parts that are applied to verify a basic concept
True
False
5. Which of the following is an Additive Manufacturing process?

Stereolithography
Room temperature vulcanization
Vacuum Casting
Silicon Rubber Molding
6. Direct Tooling is technically equivalent to

Direct Costing
Direct Manufacturing
Indirect Production
None of these
7. All Additive Manufacturing processes are called direct processes in order to indicate that the digital
process model is directly converted into a physical object, called the part, by means of a generative
machine
True
False
8. Which of the following processes can be preferably used for vacuum casting?
1. Indirect Prototyping 2. Direct Prototyping 3. Stereolithography 4. 3D printing
9. The prototyping phase follows after which of the following steps?
Evaluation
Building the application
Understanding users needs
None of the above
10. Why is prototyping essential?

To get quick feedback on the product/application
Experiment with multiple alternatives
It saves money and effort
None of the above
11. Paper and pen based sketches used for prototyping signifies which of the following?
Rapid prototyping
High-fidelity prototyping
Low-resolution prototyping
Low-fidelity prototyping
12. Which of the following statements is/are true?

It is easier to incorporate user feedback during high-fidelity prototyping compared to low-fidelity prototyping
It requires more effort and resources to incorporate user feedback during high-fidelity prototyping
It is easier to incorporate user feedback during low-fidelity prototyping compared to high-fidelity
prototyping
It requires more effort and resources to incorporate user feedback during low-fidelity prototyping
13. For Stereolithography process (SLA), the recommended minimum wall thickness of a part is;
a) 0.508 mm b) 0.408 mm c) 0.308 mm d) 0.208 mm
14. Which of the process is using extrusion concept?

Stereolithography apparatus (SLA)
Fused deposition modeling (FDM)
Selective laser sintering (SLS)
Multi-jet Modeling (MJM)
15. What happened a few years ago that helped a number of new firms enter the 3D printing industry?
A new 3D printing technique was discovered
The price of 3D printing materials dropped rapidly.
3D printing became further widespread because of the establishment of a 3D printing university.
The patents for several types of 3D printing technologies started to expire.
16. Which adjective describes what 3D printing’s manufacturing process is like?

exponential
multiplied
additive
Subtractive
17. Considering the current costs of 3D printers, which of the following 3D printing technologies is most expensive?
SLA
SLS
FDM
They all have high costs.
18. At which website can you download design files for free?1 / 1 point
Fusion
TinkerCad
MakerBot
Thingiverse
19. Using the 3D printing typology, “solutions” can be described as:1 point
component and existing
stand alone and new
stand alone and existing
component and new
20. Which of the following characteristics of 3D printing does NOT demonstrate sustainability?
It uses up less material.
Objects can be customized to your needs.
It produces little material waste.
The material costs are low.
21. How does 3D printing change the role of consumers?
It turns consumers into creators.
It does not change the role of consumers.
It turn consumers into skeptics.
It makes consumers more cost conscious
22. Which of the following is NOT important for someone interested in making their own objects with a 3D printer?
a skilled researcher on 3D printing
an idea
some knowledge of a 3D design software program
access to a 3D printer
23. When did the 3D printing industry begin to explode?

2001
2004
2009
2013
1 / 1 point
24. Which of the following fits the best definition of digital manufacturing?
Transformation of an idea into a final product that a consumer can use, including post-use disposal
Integrated, computer-based system to simultaneously create product design and manufacturing process
definitions
Software platforms that ensure consistency in data formats
Use of computer programs to design a product
25. In 4.0 industrial revolutions, choose all of the interactions possible from following options:
Human - Human Interaction
Human - Machine Interaction
Machine - Machine Interaction
None of the above
26. What is the difference in terms of feedback of employees between traditional and digital manufacturing?
In traditional manufacturing operators are seen in open loop perspective. Their focus is on machine, material and
output. There is no opportunity for feedback. In digital manufacturing, workforce is highly engaged with the
creation of the product. Workers should know how to use analysis tools and advanced machining to efficiently
produce products.
Digital manufacturing is an integrated approach to manufacturing that is centered around a computer system
27. Common benefits of a digitally-enabled supply chain compared to a traditional supply chain include (Select all
options that apply):
Reduce overproduction (and hence inventory costs)
Reduce rework
Consolidation of vendors
Launch products faster
28. Digital manufacturing means using more computers to solve the problem
True
False
1 / 1 point
29. Which of the following factors can affect market in a country?2 / 2 points
Rising Wages.
Lower Productivity Costs.
Turnover
All of the above
30. Digital manufacturing is efficient while manufacturing different products with small batches.
True
False
31. Describe the difference in terms of feedback of employees between traditional and digital
manufacturing.
In traditional manufacturing operators are seen in open loop perspective. Their focus is on machine,
material and output. There is no opportunity for feedback. In digital manufacturing, workforce is highly
engaged with the creation of the product. Workers should know how to use analysis tools and advanced
machining to efficiently produce products.
32. How would you describe the difference between the usage of computers in the third generation and
fourth generation industrial revolutions?
In the third generation industrial revolution, computers are introduced and are mostly used for basic
calculations. Whereas, in fourth generation, scope of computers is increased. They play an important
role in connecting machines and humans. Business models of many industries are changed due to
computers.
33. Which four of the following are stages of Product Lifecycle?0 / 1 point
Planning
Disposal
Simulation
Support
Design
34. In intelligent machining, sensors can only useful for human machine interaction
True False
35. According to IBM survey, in 2014 most of the cyber attacks are originated from China
True False
36. What are some of the components of the Digital Manufacturing and Design paradigm?
Components of Digital Manufacturing and Design paradigm are:
Advanced Analysis
Intelligent Machining
Advanced Manufacturing Enterprise
Digital Manufacturing Security
37. How would you define the term "Digital Thread?"

Digital Thread is the concept of seamlessly integrating information through the value chain from
requirements gathering through feasibility reviews, design, manufacturing, testing, and on to final
sustainment and disposal phases.
Production development process
Product life cycle is a sequence of all the required
activities that a company must perform to develop
manufacture and sell a product.
These activities can include marketing, research,
engineering design, quality assurance, manufacturing and
a whole chain of supplier and vendor.
The process also comprises all strategic planning, capital
investment management decision and task necessary to
create a new product.
An important part of product development is the engineering
design process, which can be designed as a process of devising a
system component or process to meet the desired requirement.
Engineering design consists of several sequential or parallel
activities that begin with identifying the need and concluding
with a ready to manufacture product.
The prototyping is considered to be the first product completed
in the production process.
It is produced using all manufacturing processes and test
procedures called by the design drawing and specification.
 The product development is evolving from a sequential process carried
out primarily by engineers to an integrated process incorporating a cross
functional team.
 Similar steps are followed in either cases, but there are accomplished
concurrently and with the higher speed in the integrated process
environment.
4 logical group of activities can be identified in product development:
 Identifying an opportunity or a demand for a new product.
 Creating a technical specification for the new product idea.
 Developing the manufacturing process to produce the new product.
 Fabricating of the new products.
 In the first group market or potential markets are analyzed to generate
customer needs, meaning that the customer will eventually generate
the requirements for the desired product features and functions.
 The market information is usually compiled by marketing specialists
who translate it into a set of product features or product descriptions
that are intended to satisfy a certain target customer base.
 This process also includes analyzing other products that meets the
target needs offered by competitors to find their point of both strength
and weakness, so that effort can be made to overcome weaknesses and
improve the desired feature.
Using a initial concept vision the design process proceeds to a
design and test the product until a preliminary design is
completed.
Then a prototype can be created and tested to make sure that the
product is functioning as it should
The prototype is considered as a first finish product in the sense
that it must be produced using all manufacturing processes, that
the actual product will go through prototyping testing. Thus the
design will be redefined and a new prototype is produced.
This will continue until no more modifications are required.
 The next step is to finalize the product documentation and then the
manufacturing process development may be initiated.
 The manufacturing process must be created so that the product can
be produced in the production facility. Purchasing new equipment
and training worker may be required if new technology is to be used.
 Tool fixtures and the sequence of steps in manufacturing processes
must all be developed to allow rapid high quality cost effective
production.
 Also it must be necessary to rearrange the production facility to
adopt for the new manufacturing process.
After the product design and development of manufacturing
process are completed. The business for producing and
shipping of the product begins.
the raw materials can be purchased and the production facility
can get into operations.
During the first two production period some problem may
arise as a result of technical production problem which will
lead to design modifications to resolve these new problems
and reach the expected production rate with the intended
quality.
Define a Product
In marketing a product is anything that can be offered to
a market that might satisfy a want or a need.
In business, Products are called as merchandise.
In manufacturing products are brought as raw material
and sold as finished goods
A service is another common product type right.
Product Design
Product Design
Product design deals with conversion of dreams into
reality; in order to fulfill human needs.
A designer produces the prototype which is used as a
sample for reproducing the particular goods in order to
satisfy customer need.
Responsibility
if producer believes that sufficient number of customers
will be satisfied then mass production may be taken up by
the production cell.
Distinctiveness: Provide excellent value for the money
spent and enhanced quality perceived.
Customer focuses and market orientation: 1. Develop and
intensive understanding of the trait of the market. 2.
recognize the competition.
Preparedness: work proceeding actual product design is
critical in determining if a product will be successful
Sharp and early product definition: 1. An outline of the concept and the benefit to
be provided. 2. A list of product attributes and features; attributes, features, in the
order ‘essential’ to desirable
Execution of activities: 1. product development team that succeeds to a better job
across the activity identifies under homework and market orientation. 2. The
team should not skip market studies and undertake trial sells.
The organizational behavior: Teams comprise members from all basic functions:
Research and development

engineering design
production
quality
sales
Project selection: Involvement of multiple projects
scatters valuable resources among many candidate
projects.
However, not all projects are likely to materialize.
successful product development
attributes
Product that sell well and make a healthy profit
1. Cost: Cost includes the cost of both producing and
developing.
2. Value: The quality of the product.
3. Time: from assessing market needs to product sales
4. Technical knowhow: the actual procedure to follow that also
should be one of the attribute for producing a successful
product.
Rapid Tooling
 Most rapid tooling today is indirect tooling. Rapid prototyping parts are
used as patterns for making moulds and dies.
 These models can be in the following manufacturing processes:

1. Investment Casting – Some rapid prototyping can be used as investment
casting patterns. Patterns must retain size when heated and not crack during
the finishing process.
Investment
Casting
The investment-casting
process, also called the lost-
wax process, was first used
during the period 4000-3500
B.C. The pattern is made of
wax or a plastic such as
polystyrene. The sequences
involved in investment casting
are shown in Figure 11.18.
The pattern is made by
injecting molten wax or plastic
into a metal die in the shape
of the object.
Rapid Tooling
 …. manufacturing processes
2. Injection Modeling
– A stereolithography machine is used to make a match-plate pattern of
the desired molding. To form this mold it is plated with metal material
such as nickel; then reinforced with ceramic.
- The two halves are separated to remove the pattern, leaving a perfect
model capable to producing thousands of injection models.
Process & machine schematics
*
Schematic of thermoplastic Injection molding machine
* Source: http://www.idsa-mp.org/proc/plastic/injection/injection_process.htm
Rapid Tooling
 …. manufacturing processes
3. Sand Casting
– A rapid prototyping model is used as a pattern which sand mold or
“casting” is built.
- Laminated Object Manufacturing (LOM) machines can be used for this
process. A LOM model can produce nearly 100 sand molds.
Rapid Manufacturing
.. Competition & challenging
 Increased competition from the global economy,
 challenge of delivering new customized products
 to meet customer demands.
 A delayed development or delivery can mean business failure.
 Several technologies collectively known as Rapid Manufacturing (RM)
have been developed to shorten the design and production cycle, and
promise to revolutionize many traditional manufacturing procedures.
Rapid Manufacturing
 Before production of a product begins, a sample or prototype is often

required as part of the design cycle, to allow demonstration, evaluation, or
testing of the proposed product.
 The fast creation of a prototype is known as Rapid Prototyping (RP), and is

generally carried out before specialized moulds, tools, or jigs are designed.
Rapid Manufacturing
 Prototyping traditionally required considerable skilled hand labour, time, and

expense, typically applied to cutting, bending, shaping, and assembling a part
from standard stock material.
 The procedure was often iterative, with a series of prototypes being built to
test various options.
Rapid Manufacturing
 For many applications, this process has been revolutionized by a

relatively recent technology known as layer manufacturing or
Solid Freeform Fabrication (SFF), in which a part of an arbitrary shape
can be produced in a single process by adding successive layers of
material.
 Increased competition from the global

Rapid Manufacturing
 RM also includes the fast fabrication of the tools required for mass
production, such as specially-shaped moulds, dies, and jigs.
 Many different layer manufacturing processes have now been developed,

using an increasing range of materials.
Rapid Manufacturing
 Theparts produced have been of steadily increasing size and

durability, and as the quality has improved layer manufacturing is
being used more and more frequently to fabricate the parts both for
production tools and functional prototypes.
 The application of layer manufacturing to make the components used

in production is termed Rapid Tooling (RT). It has been applied to
injection molding, investment casting, and mold casting processes.
Rapid Manufacturing
.... Advantages
 For some products, it can be economical to use layer manufacturing to
produce the final products themselves, sometimes in a matter of days
instead of weeks or months.
 Although the layer fabrication process itself is typically not as fast as

traditional mass production techniques, it eliminates tooling, setup, and
assembly processes, can produce parts of superior quality and complexity,
and can be ideal for making custom parts based on a customer's special
requirements.
Rapid Manufacturing
.... Advantages
 More manufacturers are taking advantages of these techniques.
 Layer manufacturing allows parts of completely arbitrary 3-dimensional
(3D) geometry to be fabricated, offering designers a new freedom to shape
parts optimally without the constraints imposed by forming, machining, or
joining.
Rapid Manufacturing
.... Advantages
 Another important advantage is that the process utilizes the computer
description of the part shape directly, and allows integration of the
Computer Aided Design (CAD) with the Computer Aided Manufacture
(CAM) of the part.
 Ittherefore allows a manufacturing cycle with a seamless transition

through the computer design, simulation, modeling, and fabrication
procedures.
Rapid Manufacturing
.... How is Rapid Manufacturing Performed?
 The first commercial layer manufacturing system intended primarily for

rapid prototyping application. Several other processes were
subsequently developed through the 1980s and 1990s.
 The technologies now available include a variety of different processes,

such as Stereolithography, Selective Laser Sintering,
Shape Deposition Manufacturing, and Laminated Object Manufacturing
.
Rapid Manufacturing
Rapid Manufacturing
 Basically, all layer manufacturing systems consist of a combination of a

computer CAD system with an operation machine to perform the
fabrication of a layer under computer control.
 First,a 3D CAD representation of the part is created by a computer

software package such as ProEngineer, SolidWorks, or Autocad.
Rapid Manufacturing
 The computer representation of the part is then sliced into layers of a

certain thickness, typically 0.1 to 0.25 mm, and their two-dimensional
(2D) profiles stored in a triangulated (tessellated) format as a .STL file.
 Second, the software converts the .STL data to machine data, which are
sent to the operation machine to generate each layer of the part by the
specific fabrication process.
Rapid Manufacturing
 The process is repeated many times, building the part layer by layer.
 The final step is finishing, removing the part from the machine, detaching
support materials, and performing any necessary cleaning or surface
finishing.
 Polishing, sealing, or painting the parts can improve their appearance.

Rapid Manufacturing
 Insome respects, layer manufacturing is related to

Computer Numerical Control (CNC) manufacture, in which a cutting
machine such as a lathe or milling machine is controlled by computer to
cut a specified shape, often with many different steps and cutting tool
changes.
Rapid Manufacturing
 However, in layer manufacturing the fabrication process builds the part

systematically by adding material instead of cutting it away, and a much
wider range of shapes can be achieved, including cavities or intricate
geometries that would be difficult or impossible to machine.
 Also, an experienced machinist may be required to design or assist the CNC

sequence, whereas layer manufacturing can be more highly automated.
Rapid Tooling
In addition to, for data inversion a tool construction is needed,
including scaling to compensate shrinkage, part line
definitions, draft angle, ejectors, sliders and so on.
Tooling mostly requires a metal process and machines that are
designed to run.
It is important to understand that ‘Direct tooling’ does not
mean that the entire tool is made. In fact, only tool components
such as cavities, sliders are generated.
The entire tool is made using these cavities and standard
components or inserts within a traditional tool making process.
Rapid Tooling
 The layer-based technology of all AM processes allows
the fabrication of interior hollow structure.
 Last because the shaping of cooling channels follows the
contour of the mold, the method is also called as
conformal cooling.
 Due to the increase in heat extraction, the productivity of
a plastic injection mold can be increased significantly.
 in addition cooling and heating channels can be designed
to obtain an integrated heat management system and thus
much more effective tools.
Rapid Tooling
Direct Processes
 Direct processes all AM processes are called as direct processes. In
order to indicate that the digital process model is directly converted into
a physical object called the part by means of generative machine.
 In contrast to this, some procedures are called as indirect process or
indirect Rapid Prototyping process. They do not apply the principle of
layered manufacturing and consequently they are not Additive
Manufacturing process.
 Actually indirect processing are copying techniques mostly based on
silicon rubber casting such as RTV.
 Since AM parts are used as masters, the term indirect Rapid Prototyping
process was established because it sounds more innovative.
Application level – indirect processes
The AM process directly delivers a geometrical extract and scaled
physical facsimile of the virtual data set. But, this process also called
comes with the disadvantage (at least with regards to most of today’s
AM processes).
 AM processes work with process and consequently with machine-
depending material and restriction in terms of color, transparency,
and flexibility.
 Shows almost no cost reduction with an increasing production
volume
 Are rather expensive when used for making many copies and
especially for series application.
To overcome these problems AM parts can be regarded
as master mold and then used for subsequent copying or
reproduction process.
The principle behind this is often called “the splitting of
capability.”
The geometrical exact part is quickly obtained from AM
process, while the desired quantity, and property such as
color and so on, comes from the subsequent copying
processes.
A copying or a follow-up process is not a layered based
Because of the marketing reasons and in order to indicate
the manufacturing speed, some call it indirect Rapid
Prototyping process as well.
For the same reason in literature sometimes the term
secondary Rapid Prototyping process is also used.
Indirect Prototyping
Indirect prototyping is applicable to improve the AM
parts property in order to fulfil the applicators
requirement, if the AM part is not capable to do so
for example
a flexible part is needed, but due to material restriction it
cannot be built directly by an AM process.
As the detailed surface is required and the parts are
mechanically loaded during the copying procedure, mainly
functional prototypes, preferably made by stereolithography or
polymer jet are used as masters.
They can be manually finished by copy before copying. The
majority of the part made by indirect processes are functional
prototype and consequently have to fulfil the same requirement.
The solid images or concept model are rarely made by indirect
processes because the higher efforts in terms of time and cost
can be can typically be not justified.
 Indirect prototyping many different secondary processes can be used.
 The most prominent one is also called as Room Temperature
Vulcanization (RTV in short. It is also called as vacuum casting or it is
called as silicon rubber mold.
 Like silicon rubber molding most of the secondary processes are
completely or partially manual processes; with long cycle time and
therefore, only used for small series or one of a kind production.
 For instance a plug system requires plug housing of different colours
and transparency.
 Based on two part additive manufacturing master of a housing, a
silicon rubber mold is to be made.
As they are prototypes made from prototyping materials, the
system elements are no series products. Even if they are they
function very well.
Prototype parts from soft materials for example, gaskets that is
rubber often have a very complex shapes.
This is especially true for gaskets for car mirror or fixation that
must fulfil many functions such as sealing against water,
fixation of the mirror and parts of the window, replacement of
placement of cables, attractive optical appearance and
integration of adjacent extruded sealing.
Indirect Tooling
Indirect tooling is based on the same copying procedure as
indirect processes.
It is not that goal to obtain a final part, but a tool that provides
the basis for a small or medium size batch production of final
parts or products.
In contrast to series tools made from the tool steel it can be
made quickly and inexpensively.
Like indirect prototyping, indirect tooling uses additive
manufactured masters thus avoiding milling grinding and other
EDM processes
Thank you

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RAPID PROTOTYPING /

Rapid Prototyping is Positive process

“Rapid Manufacturing” is creating durable and safe products for

Seen here attached to the US Navy's M4A1 machine

Virtual CAD model using computer

Obtain the contour by slicing the CAD model on the computer

 Two basic methodologies:

2. Production of tooling by rapid prototyping for use in further

 Tools are often complex and need to be wear resistant for

 By using rapid prototyping, tooling and design cost may be

 These may be forms of basic RP processes, such as SLS, or

 Direct Tooling / Direct Fabrication Processes

 To make metal tooling direct from CAD file through

 Rapid tool – A process which uses SLS to sinter poly-

 LOM Composite – A method of using ceramic composite

 Sand Moulding – A rapid prototyping technique that

 Laser Engineering Net Shaping (LENS) – A process that

 Although the properties of rapid prototyping materials

 There will always be a need to transfer parts fabricated in a

 Consequently,numerous material transfer technologies

 Typically a part made by the RP system is used as a pattern

 As in the case of the direct fabrication processes discussed

 However, of the more than two dozen such methods

 Fixed surface mode: The resin is stored in a container with

 Scanning stereolithography. The laser beam is rastered onto

Maximum build size 1500mm x 750mm

• The application of rapid prototyping (RP)

• Microstereolithography, derived from conventional

• Whereas in conventional stereolithography the laser

• The monomers used in RP and micro-

• In microstereolithography the solidified polymer is

• Two-photon provides a further

• Special initiator molecules in the monomer only

• Two-photon polymerization can occur everywhere

Current materials in Additive

Challenges in AM materials properties

Anisotropy is the property of substances to exhibit variations in physical properties

Stratasys Dimension SST 1200

Courtesy, Dr. Robin Richards,

Accuracy, mm (in) ± 0.127 (± 0.005) ± 0.127 (± 0.005)

Layer thickness mm (in) “Standard” — 0.245 (0.010) User selectable:

Size, w x d x h, mm (in) 914 x 686 x 1041 864 x 686 x 1041

Fused Deposition Modeling (FDM)

2. The nozzle heats up the wire and extrudes

3. A computer controls the nozzle movement

4. In the newest models, a second nozzle

Maximum build size 20” x 20” x 20” • Economical (inexpensive materials)

Available materials Thermoplastics

KEY APPLICATION AREAS

(FDM)Do it Yourself FDM rapid prototyping systems

3. Additive manufacturing is generally a ________ process.

5. Which of the following is an Additive Manufacturing process?

6. Direct Tooling is technically equivalent to

10. Why is prototyping essential?

12. Which of the following statements is/are true?

14. Which of the process is using extrusion concept?

16. Which adjective describes what 3D printing’s manufacturing process is like?

23. When did the 3D printing industry begin to explode?

37. How would you define the term "Digital Thread?"

Research and development

 These models can be in the following manufacturing processes:

Schematic of thermoplastic Injection molding machine

 Before production of a product begins, a sample or prototype is often