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4-Introduction To RP

The document discusses rapid prototyping (RP) which refers to technologies that can automatically construct physical models from CAD data in minimum lead time. It describes various RP methods like stereolithography, laminated object manufacturing, and selective laser sintering. Benefits of RP include reduced lead times for prototypes and ability to visualize designs. Limitations include part accuracy issues and limited material variety.

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Fawad Hussain
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© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
71 views

4-Introduction To RP

The document discusses rapid prototyping (RP) which refers to technologies that can automatically construct physical models from CAD data in minimum lead time. It describes various RP methods like stereolithography, laminated object manufacturing, and selective laser sintering. Benefits of RP include reduced lead times for prototypes and ability to visualize designs. Limitations include part accuracy issues and limited material variety.

Uploaded by

Fawad Hussain
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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Introduction

To
Rapid Prototyping (RP)
Layer Manufacturing
Direct CAD Manufacturing
Solid Freeform Fabrication
Rapid Prototyping and Manufacturing (RPM)
Fair Use Notice

The material used in this presentation i.e., pictures/graphs/text, etc. is solely


intended for educational/teaching purpose, offered free of cost to the students for
use under special circumstances of Online Education due to COVID-19 Lockdown
situation and may include copyrighted material - the use of which may not have
been specifically authorized by Copyright Owners. It’s application constitutes Fair
Use of any such copyrighted material as provided in globally accepted law of
many countries. The contents of presentations are intended only for the attendees
of the class being conducted by the presenter.
What is RP?
The term rapid prototyping (RP) refers to a class of technologies that
can automatically construct physical models from Computer-Aided
Design (CAD) data.
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, given that a computer


model of the part has been generated on a CAD system.
Material used in RP, may be
• Liquid monomers deposited layer by layer and cured into
solid polymers
• Powders that are aggregated and bonded layer by layer
• Solid sheets that are laminated to create the solid part
RP Basic Steps

All RP techniques employ the same basic five-step process.

1 Create a CAD model of the design

2 Convert the CAD model to STL format (stereo lithography)

3 Slice the STL file into thin cross-sectional layers

4 Construct the model one layer on top of another layer

5 Clean and finish the model


RP Methods/Types/Classification
The RP can be classified on form of the starting material:
1. Liquid-based
– Stereo lithography
RP process for fabricating a solid plastic part out of a
photosensitive liquid polymer using a directed laser beam to
solidify the polymer; Each layer is 0.076 mm to 0.50 mm (0.003 in
to 0.020 in.) thick
– Solid ground curing
Like stereo lithography, SGC works by curing a photosensitive
polymer layer by, Instead of using a scanning laser beam to cure
a given layer, the entire layer is exposed to a UV source through a
mask above the liquid polymer
– Droplet deposition manufacturing
• Starting material is melted and small droplets are shot by a nozzle
onto previously formed layer
RP Methods/Types/Classification
The RP can be classified on form of the starting material:
. Solid-based
– Laminated object manufacturing
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
– Fused deposition modeling
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
RP Methods/Types/Classification
The RP can be classified on form of the starting material:
3. Powder-based
– Selective laser sintering
Moving laser beam sinters heat‑fusible powders
(Powder that melts) in areas corresponding to the CAD
geometry model one layer at a time to build the solid
part

– Three dimensional printing


Part is built layer-by-layer using an ink-jet printer to
eject adhesive bonding material onto successive
layers of powders
BENEFITS OF RP
Design phase requires a physical model of a new part or product
rather than just a computer model or line drawing/2D
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 and shortcomings
Excellent visual aids for communicating
Prototypes can be used for design testing.
Reduced lead times to produce prototypes
Used to make production-quality parts
Improved ability to visualize part geometry
Early detection of design errors
BENEFITS OF RP
Comparison of different shapes and styles to determine
aesthetic appeal
Wind tunnel testing shapes
Pattern is created by RP and the pattern is used to fabricate the
tool
RP is used to make the tool itself, such as a die
Small batches of plastic parts that could not be
economically molded by injection molding because of the
high mold cost
Parts with intricate internal geometries that could not be
made using conventional technologies without assembly
One-of-a-kind parts such as bone replacements that must
be made to correct size for each user
Limitations/Problems with Rapid Prototyping

• Part accuracy:
– Staircase appearance for a sloping part surface
due to layering
– Shrinkage and distortion of RP parts
• Limited variety of materials in RP
– Mechanical performance of the fabricated parts
is limited by the materials that must be used in
the RP process

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