RAPID PROTOTYPING(RPT)

Revolutionary and powerful technology with wide range of application.
The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance.

1. RAPID PROTOTYPING MANOJ K 1 ST SEM M.TECH (CIM) TECHNICAL SEMINAR

2. INTRODUCTION Revolutionary and powerful technology with wide range of application. The process involve quick building up of a prototype or working model for the purpose of testing the various design features, ideas, concepts, functionality, output and performance. Group of techniques used to quickly fabricate a scale model of a part or assembly using 3D CAD data. RP is an "additive" process, most machining processes are "subtractive" processes 2 16/12/2016

3. HISTORY 3 In 60’s, first RPT became accessible. In 70’s, Herbert Voelcker , engineering professor developed the basic tools of mathematics that describe the 3D aspects. In 80’s Carl Deckard ,researcher from the University of Texas. He pioneered the layer based manufacturing, he thought of building up the model layer by layer. He printed 3D models by utilizing laser light for fusing metal powder in solid prototypes, single layer at a time. Technique called ‘Selective Laser Sintering’. 16/12/2016

4. HISTORY(Cont...) 4 Nowadays The computer engineer has to simply sketch the ideas on the computer screen with the help of a design program. CAD allows to make modification as required and can create a physical prototype that is a precise and proper 3D object. 16/12/2016

5. WHAT IS RAPID PROTOTYPING? 5 “Process of quickly building and evaluating a series of prototypes" Early Throughout the design process 16/12/2016

6. WHY RAPID PROTOTYPING? 6 Effective communication. Development time. Costly mistakes. To minimize sustaining engineering changes. To extend product lifetime by adding necessary features 16/12/2016

7. Cont… 7 The trends in manufacturing industries continue to emphasize the following: Increasing number of variants of products. Increasing product complexity. Increasing product lifetime. Decreasing delivery time. 16/12/2016

8. HOW DOES RP WORK? 8 The process begins with taking a virtual design from modelling or CAD software. The 3D printing machine reads the data from the CAD drawing lays down successive layers of liquid, powder, or sheet material — building up the physical model from a series of cross sections. These layers are automatically joined together to create the final shape. 16/12/2016

9. APPLICATIONS 9 1. RAPID TOOLING Patterns for Sand Casting Patterns for Investment Casting Pattern for Injection moldings   2. RAPID MANUFACTURING Short productions runs Custom made parts On-Demand Manufacturing Manufacturing of very complex shapes 16/12/2016 3. AEROSPACE & MARINE Wind tunnel models Functional prototypes Boeing’s On-Demand-Manufacturing   4. AUTOMOTIVE RP SERVICES P roduction level Reduced time to market Functional testing Dies & Molds

10. Cont… 16/12/2016 10 5. BIOMEDICAL APPLICATIONS Prosthetic parts Presurgical planning models Mechanical bone replicas Anthropology Forensics 7. ARCHITECTURE 3D visualization of design space Iterations of shape Sectioned models 6. FASHION & JEWELRY Shoe Design Jewellery Pattern for lost wax Other castings

11. BASIC PROCESS 16/12/2016 11 Create a CAD model of the design Object to be built is modelled using CAD software. Solid modellers like Pro-E yield better results. Existing CAD file may also be used Convert the CAD model to STL (Standard Tessellation Language) format STL format is the standard of rapid prototyping industry. This format represent 3D surface as an assembly of planar triangles and describes only surface geometry.

12. Cont… 16/12/2016 12 Slice the STL file into thin cross-sectional layers Several programmes are available for this. STL models are sliced into a number of layers (.01mm to .7mm). Orientation size and location are adjusted using the software. Construct the model one layer atop another RP machine builds one layer at a time from polymers, paper, or powdered metal. Fairly autonomous needing little human intervention. Clean and finish the model Post processing step. Prototype may require minor cleaning and surface treatment.

13. RP TECHNIQUES 16/12/2016 13 Most commercially available rapid prototyping machines use one of the four techniques Stereo lithography (SL or SLA). Laminated object manufacturing. Selective Laser Sintering. 3D ink jet printing.

14. STEREO LITHOGRAPHY(SL) 16/12/2016 14 Builds 3D model from liquid photo sensitive polymers when exposed to UV rays. Model is built upon a platform situated just below the surface of liquid epoxy or acrylate resin. A low power highly focused UV laser traces out the first layer, solidifying model cross section. An elevator incrementally lowers the platform into the liquid polymer. Process is repeated until prototype is complete. Model is the placed in an UV oven for complete curing.

15. Cont… 16/12/2016 15

16. Laminated Object Manufacturing 16/12/2016 16 Layer of adhesive coated sheet materials are bonded to form a prototype. Paper laminated with heat activated glue is rolled up on spools. Heated roller applies pressure to bond the paper to the base. Feeder/collector mechanism advances paper. Laser cuts the outline of first layer. Platform is lowered and fresh material is advanced. Process is repeated and a roller bonds the layers.

17. Cont… 16/12/2016 17

18. SELECTIVE LASER SINTERING 16/12/2016 18 Uses laser beam to selectively fuse powdered materials such as nylon, elastomer or metal into a solid object. Parts are built on a platform which sits below the surface in a bin of heat fusible powder. Laser traces the pattern of first layer, sintering it together. Then platform is lowered, powder is reapplied and process is repeated.

19. Cont… 16/12/2016 19

20. 3D INK JET PRINTING 16/12/2016 20 Parts are built upon a platform situated in a bin full of powder material. An ink-jet printing head selectively deposits or "prints" a binder fluid to fuse the powder together in the desired areas. Unbound powder remains to support the part. The platform is lowered, more powder added and levelled, and the process repeated. Finished parts can be infiltrated with wax, glue, or other sealants to improve durability and surface finish. Typical l ayer thicknesses are on the order of 0.1 mm. This process is very fast, and produces parts with a slightly grainy surface. There are also other different types of 3d printing available in the market which gives very good accuracy.

21. Cont… 16/12/2016 21

22. ADVANTAGES 16/12/2016 22 Accuracy Product complexity Minimal wastage No part supports required High speed

23. DISADVANTAGE 16/12/2016 23 Not suitable for large sized applications. Limited materials Poor Surface finish High machine cost

24. CONCLUSION 16/12/2016 24 Modern CNC machines have high removal rates which helps in fast machining. For certain applications machining will continue to be a useful manufacturing process. One should regard RPT as one more option in the toolkit for manufacturing parts. No tooling: less tools is better One shot operation: no assembly of parts Reduce lead time: less time improve production rate Flexible: modification, addition of parameters, scaling Clean & safe operation

25. REFERENCES 16/12/2016 25 Rapid Manufacturing , Flham D.T & Dingoy S.S Verlog London 2001. Rapid Prototyping , Terry Wohlers Wohler’s Report 2000” Wholers Association 2000.

26. THANK YOU 16/12/2016 26