Rapid Prototyping: Basic process of RP Prototyping of processes

Rapid Prototyping:
What is Rapid Prototyping
Basic process of RP
Prototyping of processes:
1. Stereolithography
2. Fused Deposition Modeling
3. Laminated Object Manufacturing
Advantages & disadvantages of above processes.
Applications
Future development
Conclusion
References

1. Unit -6(b) RAPID PROTOTYPING Presented By Dr. Sivasankara Raju R Associate Professor Dept. of Mechanical Engg . AITAM, Tekkali-532201 Andhra Pradesh

2. CONTENTS What is Rapid Prototyping Basic process of RP Prototyping of processes: 1. Stereolithography 2. Fused Deposition Modeling 3. Laminated Object Manufacturing Advantages & disadvantages of above processes. Applications Future development Conclusion References

3. Prototype Fabrication Techniques Laser Cutting Waterjet Cutting EDM EB CNC machining Subtractive Additive SLA, SLS, FDM, Direct Casting LOM Laser Bending Electromagnetic Forming, Adaptive Die Casting, Casting, Forging Formative

4. History of RP

5. What is Additive Manufacturing? Additive Manufacturing is a method in which the part is created by a layer- additive process. Using a specialized software, a 3-D CAD model is cut into very thin layers or cross-sections. Then, depending on the specific method used (sintering, fused deposition, etc), the AM machine constructs the part layer by layer until a solid replica of the CAD model is generated. The advantages of this process is clear: development of physical models can be accomplished in significantly less time as compared to the machining process. Machining is a subtractive process, beginning with a solid piece of stock. The machinist must carefully remove material until the desired geometry is achieved. For complex part geometries , this is an exhaustive , time consuming , and expensive process . Some parts are even too complex to be machined.

6. Trends in manufacturing industries emphasis the following Increasing the no of variants of products. Increase in product complexity. Decrease in product lifetime before obsolescence. Decrease in delivery time. Product development by Rapid prototyping by enabling better communication.

7. Conventional Machining Its not suitable for complex shapes because they are difficult to machine. Time consuming Very costly Tedious or very laborious. Skilled operator is required. Accuracy will be less. Increased product development time.

8. Advantages of AM Rapid Prototyping can give with concept proof that would be needed for attracting funds. The Prototype hints the user about the final product look . It can increase early visibility. Easy to find design flaws in the early stages of developmental. Active participation among the users and producer is encouraged. It is cost effective,as development cost reduces. Any deficiency in the earlier prototypes can be detected and rectified in time. There is better communication between the user and designer. The high-quality product is delivered. Rapid prototyping helps development time and costs.

9. Disadvantages Of Rapid Prototyping It fails in exact replication of the real product or system. Some important developmental steps might get omitted to get a quick and cheap working model. This turns out to be one of the greatest disadvantages of rapid prototyping. Another disadvantage is that many problems are overlooked resulting in endless corrections and revisions. Unsuitable for large sized applications. Compared to user’s high expectations, the prototype’s performance and the designer are unable to deliver these. The producer may produce an inadequate system that is unable to meet the overall demands of the organization. Over involvement of user might hamper optimization of the program.

10. AM for Product Development Process Concept Development System-Level Design Detail Design Testing & Refinement Production Ramp-Up Concept Development System-Level Design Detail Design Production Ramp-Up Testing & Refinement

11. Input Physical Objects CAD Models STL Files Sliced Model Files Material Paper, Resins, Nylon, ABS, Wax, metals, ceramics Liquid Powder Solid Method Photocuring Cutting&Gluing Melting&Solidifying Binding Applications Design Engineering, Analysis & Planning Manufacturing & Tooling RP

12. Create a CAD model of the design Convert the CAD model to STL format Slice the STL file into layers Construct the physical model layer by layer Clean and finish the model Computed Tomography Scan The tessellated model

13. 1. What is Rapid Prototyping Rapid Prototyping: Traditional manufacturing: additive material subtractive material

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

15. Commonly Used Terms for Additive Manufacturing Rapid Prototyping (RP) Direct CAD Manufacturing Desktop Manufacturing Instant Manufacturing CAD Oriented Manufacturing Layer Manufacturing Material Deposit Manufacturing Material Addition Manufacturing Solid Freeforming

16. Advantages of AM Reduce product development time and cost Get products to market sooner Enhance communications between marketing, engineering, manufacturing, and purchasing Present physical model at critical design reviews Perform functional prototype testing before committing to tooling Generate precise production tooling Staircase effect Layer thickness Accuracy Part orientation Support Structures Issues in Layered-Based Manufacturing

17. PROTOTYPING PROCESSES

18. AM Processes Material Basic Process Process Name Solid Laminated Object Manufacturing (LOM) Fused Deposition Manufacturing (FDM) Gluing Sheets Melting+Solidification Powder Selective Laser Sintering (SLS) 3D Printing Material powder Material+Binder Liquid Solid Ground Curing (SGC) Stereolithography (SLA) Liquid Polymerization

19. 2.1 Stereo-Lithography (SL ) 1. The elevator lowered by 1 layer deep; 2. The Blade sweep across the vat, apply an even layer of resin on top of the part; 3. As the laser beam strikes the resin surface, the liquid resin is hardened to a solid plastic; 4. Loop through the three steps to cure a new layer.

20. Advantages Disadvantages Parts have best surface quality High Accuracy High speed Finely detailed features like thin vertical walls, sharp corners & tall columns can be fabricated with ease. It requires Post Processing. i.e. Post Curing. Careful handling of raw materials required. High cost of Photo Curable Resin Applications: Investment Casting. Wind Tunnel Modeling. Tooling. Injection Mould Tools.

21. Materials: Photocurable resins: acrylate polyurethane Build Materials Used: Epoxy Resin, Acrylate Resin Epoxy Resin has better material properties and less hazardous but require large exposure time for curing.

22. 2.2 Fused Deposition Modeling (FDM) 1. Extrusion head and elevator move to start position; 2. The head extrude layer of support; 3. The head extrude layer of model; 4. Loop through the three steps to build the next layer.

23. fused-deposition-modeling- fdm -technology- givefastlink

24. Materials: thermoplastic material wax polycarbonate elastomer - Advantages: Strength and temperature capability of build materials. Safe laser free operation. Easy Post Processing. Disadvantages Process is slower than laser based systems. Build Speed is low. Thin vertical column prove difficult to build with FDM. Physical contact with extrusion can sometimes topple or at least shift thin vertical columns and walls.  

25. 2.4 Laminated Object Manufacturing (LOM) 1. The sheet material is stretched from the supply roller to the take-up roller; 2. The heated laminated roller passes over the sheet bonding it to the previous layer; 3. Laser cuts the profile of that layer and hatching the excess material for later removal; 4. Loop through the three steps to form a new layer.

26. lom -process-from- helisys - givefastlink

27. Materials: Sheet material: paper plastic ceramic composite etc.

28. Selective Laser Sintering (SLS) Applications: 1. As conceptual models. 2. Functional prototypes. 3. As Pattern masters. sls-3d-printing-technology-givefastlink how-does-selective-laser-sintering- sls -work- givefastlink

29. Advantages: 1. Wide range of build materials. 2. High throughput capabilities. 3. Self supporting build envelop. 4. Parts are completed faster. 5. Damage is less. 6. Less wastage of material. Disadvantages: 1. Initial cost of system is high. 2. High operational and maintenance cost. 3. Peripheral and facility requirement.

30. 3. Application cases of RP Common applications of the RP technology: Design concept models Medical application Computer Tomography - CT scanner

31. Marketing models for tenders, customer feedback, presentations and brochures Rapid prototyping is widely used in the automotives. AUDI RSQ

32. ADVANTAGES: Reduced the time. Accuracy is increased. Parts can be used immediately after the process and no post curing is required. DISADVANTAGES: Although there is some choice of materials including paper, plastic, ceramic and composite, we can not used metal as a material to create prototype.  

33. Applications of AM Design CAD model verification Visualizing objects Proof of concept Market and presentation application Manufacturing and Tooling Tooling mold parts (soft tooling and hard tooling) Casting EDM electrodes Master models Engineering Analysis and Planning Form and fit Stress analysis Mock-up parts Pre-production parts Diagnostic and surgical operation planning Industries Aerospace Jewelry Consumer electronics Automotive Biomedical Tableware

34. One such improvement is increased speed of part building “Rapid" prototyping machines. Another future development is improved accuracy and surface finish. The introduction of non-polymeric materials, including metals, ceramics, and composites, represents another much anticipated development. These materials would allow RP users to produce functional parts. Another important development is increased size capacity Advances in computerized path planning, numeric control, and machine dynamics are increasing the speed and accuracy of machining. Future development:

35. CONCLUSION After studying the rapid prototyping we can conclude that the process(RP) is really a efficient , flexible process with better scope in future as compared to old prototyping techniques. It necessiates rapid production of prototype in less time and cost.

36. Reference www.wikipedia.in/rapidprototyping S.H. Ahn, M. Montero, D. Odell, S. Roundy, P.K. Wright, Anisotropic material properties of fused deposition modeling ABS, Rapid Prototyping J. 8 (4) (2002) 248–257. K. Thrimurthulu, P.M. Pandey, N.Venkata Reddy, Optimum part deposition orientation in fused deposition modeling, Int. J. Mach. Tools Manuf. 44 (2004) 585–594.

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