RAPIDPROTOTYPING

COMPUTER AIDED MANUFACTURING ASSIGNMENT Presented by S.SAMPATH KUMAR. M.Tech Ist year. (Product design and manufacturing) Pondicherry engineering college.
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CONDENT
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Definition of Rapid Prototyping. Why is Rapid Prototyping Important? Classification of Rapid Prototyping Technologies. Advantages of Rapid Prototyping. Disadvantages of Rapid Prototyping. Applications and Benefits of Rapid Prototyping.
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The user can give an early feedback regarding the 2/9/2012 ©2007 John Wiley & . features. performance and output. This process of development of working model is quite quick. ideas.INTRODUCTION OF RAPIDPROTOTYPING Rapid prototype is a process wherein a working model or prototype is developed for the purpose of testing the various product features like design. functionality.

. The product can be produced if the prototype meets the 2/9/2012 requirements ©2007 John Wiley & of all designing objectives ..INTRODUCTION OF RAPIDPROTOTYPING cont. it is possible to correct the defects or problems in the design by taking corrective measures. The Rapid prototype that prototyping is based on is the developed by the process of rapid performance of earlier designs. Hence.

given thatWiley & a computer 2/9/2012 ©2007 John .Definition of Rapid Prototyping (RP) A family of fabrication processes developed to make engineering prototypes in minimum lead time based on a CAD model of the item • Traditional method is machining – Can require significant lead-times – several weeks. depending on part complexity and difficulty in ordering materials • RP allows a part to be made in hours or days.

Why is Rapid Prototyping Important? • Product designers want to have a physical model of a new part or product design rather than just a computer model or line drawing – Creating a prototype is an integral step in design A virtual prototype (a CAD model of the part) may not be sufficient for the designer to visualize the part adequately – Using RP to make the prototype. the designer can see and feel the part and assess its merits 2/9/2012 ©2007 John Wiley & and shortcomings – .

Solid-based a) 2/9/2012 b) .• There are various ways to classify the RP techniques that have currently been developed The RP classification used here is based on the form of the starting material: 1. Classification of RP Technologies • Liquid-based a) Stereolithography Fused Deposition Modeling (FDM) Laminated Object Manufacturing (LOM) ©2007 John Wiley & 2.

and (2) after several layers have been added so that the part geometry gradually takes form.2 Stereolithography: (1) at the start of the process.Stereolithography Figure 34. in which the initial layer is added to the platform. 2/9/2012 ©2007 John Wiley & .

each layer is added onto the previous layer to gradually build the 3-D geometry The first addition RP technology introduced 1988 by 3D Systems Inc.Stereolithography (STL) RP process for fabricating a solid plastic part out of a photosensitive liquid polymer using a directed laser beam to solidify the polymer • Part fabrication is accomplished as a series of layers . based on the©2007 Johnof Charles Hull work Wiley & 2/9/2012 • .

).Figure 34. Inc.3 A part produced by stereolithography (photo courtesy of 3D Systems. 2/9/2012 ©2007 John Wiley & .

com/video.acucast.htm 2/9/2012 ©2007 John Wiley & .SLA Video http://www.

Fused Deposition Modeling 2/9/2012 ©2007 John Wiley & .

1 s 2/9/2012 ©2007 John Wiley & • .RP process in which a long filament of wax or polymer is extruded onto existing part surface from a workhead to complete each new layer • Fused Deposition Modeling (FDM) Workhead is controlled in the x-y plane during each layer and then moves up by a distance equal to one layer in the z-direction Extrudate is solidified and cold welded to the cooler part surface in about 0.

polyolefin.Fused Deposition Modeling FDM Stratasys. ABS • water soluble or wax supports • • • • • 2/9/2012 ©2007 John Wiley & . Eden Prarie.005” casting and machinable waxes. MN patent 1992 robotically guided fiber extrusion accuracy ± 0.

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FDM material 2/9/2012 ©2007 John Wiley & .

Laminated Object Manufacturing Figure 34.5 Laminated object manufacturing. 2/9/2012 ©2007 John Wiley & .

Solid physical model made by stacking layers of sheet stock. each an outline of the cross-sectional shape of a CAD model that is sliced into layers • Starting sheet stock includes paper. metals. or fiberreinforced materials • The sheet is usually supplied with adhesive backing as rolls that are spooled between two reels • After cutting. plastic. excess material in the 2/9/2012 ©2007 John Wiley & layer remains in place to support the Laminated Object Manufacturing (LOM) . cellulose.

Logon the website : www.com www.xpress3d.acucast.com 2/9/2012 ©2007 John Wiley & .

2/9/2012 ©2007 John Wiley & • • • . As the development costs are reduced.ADVANTAGES • High quality product is easily delivered by way of Rapid prototyping. Rapid prototyping enables development time and costs. Rapid prototyping proves to be cost effective. There are many innovative ways in which Rapid prototyping can be used.

The producer may produce an inadequate system that is unable to meet the overall demands of the organization. John Wiley & 2/9/2012 ©2007 • • . The user may have very high expectations about the prototype’s performance and the designer is unable to deliver these.DISADVANTAGES • One more disadvantage of rapid prototyping is that it may not be suitable for large sized applications.

3.RP Applications Applications of rapid prototyping can be classified into three categories: 1. Design Engineering analysis and planning Tooling and manufacturing 2. 2/9/2012 ©2007 John Wiley & .

Design Applications • Designers are able to confirm their design by building a real physical model in minimum time using RP Design benefits of RP: – • Reduced lead times to produce prototypes Improved ability to visualize part geometry Early detection of design errors Increased capability to compute mass properties ©2007 John Wiley & – – – 2/9/2012 .

Engineering Analysis and Planning • Existence of part allows certain engineering analysis and planning activities to be accomplished that would be more difficult without the physical entity – Comparison of different shapes and styles to determine aesthetic appeal Wind tunnel testing of streamline shapes Stress analysis of physical model – – Fabrication of pre-production parts for process 2/9/2012 ©2007 John Wiley & planning and tool design – .

• Indirect RTM method Direct RTM method 2.Tooling Applications • Called rapid tool making (RTM) when RP is used to fabricate production tooling Two approaches for tool-making: 1. 2/9/2012 ©2007 John Wiley & .

Thanking you… 2/9/2012 ©2007 John Wiley & .