ME 252

Geometric Modeling

Drawings
and
Assemblies

Part #04
Chapter Objectives
• Understand the basics of Engineering Drawings
• Outline the industry standards followed by designers
for Engineering Drawings
• Introduce the SolidWorks environment to execute
Engineering Drawings procedure
• Give an overview of assembly concepts used to
assemble created parts
Drawings
Dimensioning
• The way a designer displays the dimensions on the
views implies how to manufacture the part
• Hence the designer must have prior knowledge about
– Drafting and Communication rules
– Manufacturing
– Common stock shapes available off the shelf
– Tolerances
ASME Abbreviation Rules
1) Minimize using abbreviations
2) Pay attention to foreign use
3) Pay attention to clarity
4) Be aware of duplicates
5) Define when extensively used
6) Take advantage of single use
7) Avoid using non standard abbreviations
8) Follow military rules
9) Use all capital letters
10) Avoid using subscripts
Sample Abbreviations
ASME Drafting Rules
1) Use Tolerances
2) Provide full feature definition
3) Show only what is needed
4) Follow functional requirements
5) Do not specify manufacturing methods
6) Show processing dimensions
7) Show Dimensions clearly
8) Use linear dimensions for specific parts
9) You may not specify 90 degree angle
10) Keep temperature in mind
11) Understand geometric tolerances
Sample Drafting Rules
ASME Dimensioning Rules
1) Be careful when to use a zero before the decimal point
2) Do not use a zero or a decimal point for a whole number
millimeter dimension
3) Do not add a zero to the decimal millimeter dimension
4) Use the same number of decimal places as its tolerance for inch
dimension
5) Show decimal points clearly
6) Use dimension lines correctly
7) Group dimension lines
8) Space dimension lines
9) Do not cross dimension lines
10) Do not cross extension (projection) lines
11) Use leaders (leader lines) if needed
ASME Dimensioning Rules Example
Dimensions (SolidWorks Types of Dims)
 Drawing Content and Layout
Drawing Content includes views, dimensions, title block, notes,
tolerances, balloons, hole callouts, weld symbols, surface finish
symbols, surface roughness values, and bill of materials (BOM)
Types of Projection
Projection is used to generate 2D views from 3D models
The two types of projection commonly used are:
First-angle projection
Third-angle projection
Views
 CAD/CAM systems offer different views to convey model
design
 Some of the view types offered by SolidWorks are
 Named (orthographic) views
 Section view
 Projected view
 Auxiliary view
 Detail view
 Crop view
 Broken-out section
 Broken view
 Relative view
Views example
Sheets and Title Blocks
 A drawing may include multiple sheets
 Sheets help add more views to a drawing
Design Checker
The tasks of the design checker are to
 Ensure that the design documented in the drawing can be
produced with least manufacturing cost
 Look for inconsistencies in the part dimensioning
 Check the part tolerances and ensure that manufacturing
processes can produce them
 Check the dimensioning scheme according to the set
standards
 Ensure that the materials are specified
Design Checker
Assembly Modeling
INTRODUCTION

 In most engineering designs the products of interest is

a composition of parts, formed into an assembly
 Modelling and representing assemblies as well as
analyzing assemblies are all relevant issues to
geometric modelling and CAD/CAM technology
 Parts can be modelled separately often by different
members of the design team on a CAD/CAM system
 Instances (copies) of these parts can be merged into a
base part or a host to generate the assembly model
Hierarchy and Mating
 Assembly modelling raises two modelling issues that
do not exist at the part modelling level: hierarchy and
mating
 Individual parts and subassemblies must be
assembled in the right hierarchy (sequence), which is
captured (stored) in an assembly tree for each
assembly or product
 Mating conditions are used to determine the mating
(spatial relationships and orientations) between the
assembly parts; for example, the axes of a shaft and a
hole may have to be lined up, in which case a
concentric mating condition is required
Assembly Modelling
Assembly Mates
 Assembly procedure applies mating
conditions (mates) to constraint parts in the
assembly
 A mate positions two components relative to
one another
 A mate applies to a face, an edge, a point or
an axis
Assembly Mates Types
Mating Conditions
 The MCS of the host becomes the global
coordinate system of the assembly. And Part MCS
becomes the local coordinate system for this part.
 Common mating conditions
– Concentric
– Coincident
– Tangent
– Coplanar
– Parallel faces
– Perpendicular faces
Coincident mating condition
Concentric mating condition
Tangent mating condition
Coplanar mating condition
Assembly Example
Assembly Modeling Approaches

 Bottom-Up assembly Modeling

 Create the parts
 Insert them into assembly model
 Use mates to position and orient parts
Bottom-up assembly approach
 Individual parts are created independently
 Inserted into an assembly
 Mating conditions are used to locate and orient each inserted part
correctly as required by the assembly model

 When a part is inserted into assembly, a copy (instance) is inserted

in reality. There is a link between the instance and the original part
 Advantages:
– Preferred technique if the parts have already been constructed
– Allows designer to focus on individual parts
– Makes it simpler and easier to maintain the relationship and
regeneration behaviour of parts than in top-down approach
Example (bottom-up)
Assembly Modeling Approaches

 Top-Down Assembly Modeling (in-context

approach)
 Create layout sketch
 Use layout sketch to define the component
shape, size and location
Top-Down assembly approach
 Begins with an assembly layout sketch
 The layout defines components in the context of
an assembly
 These components are empty as they do not have
any external references to actual parts and
subassemblies files yet
 Assembly layout defines skeletal, space claim
 The space claim is the most important property of
assembly layout as it shows where each assembly
components belongs

In the top-down assembly design approach, components are created

inside the Assembly Design workbench. Therefore, there is no need to
create separate part files of the components.
Example
Assembly Drawing

 Similar to part drawings

 Assembly drawings use BOMs and balloons to
fully document the assembly
Assembly Exploded View
In this view the components of the assembly are
moved along the axes of the assembly modeling
space
Assembly analysis
Generate assembly drawings
Generate parts list
Generate an exploded view
Generate sectional views
Perform interference checking
Perform collision detection
Perform mass property calculations
Assembly Motion Study
 Assembly motion study helps one to check
the assembly motion
 SolidWorks provides two types of motion for
an assembly
 Animation
 Basic motion
Assembly Motion Study
Interference and Collision Detection

 Interference and collision detection help

check whether assemblies are created
correctly and whether the dimensions of their
parts are correct relative to each other
 Interference analyzes static parts where as
collision analyzes moving parts
Assembly Design tables
 A design table is an Excel spreadsheet that is
used to create multiple configurations in a
part or an assembly document
 Design tables can be created to control
configuration of parts, mates as well as
distance and angle relationship between parts
Assembly Modelling

 A designer can analyze parts separately

 After the parts are created, the designer can
assemble the parts and analyze the assembly
 Assembly analysis may include interference
checking, mass properties, kinematics and
dynamic analysis and finite element analysis
 CAD systems establish a link between an
assembly and its individual parts such that the
designers need only change individual parts for
design modification, and the system updates the
assembly model automatically
Assembly Tree
Assembly Planning
 Identify the dependencies between the
components of an assembly
 Identify the dependencies between the
features of each part
 Analyze the order of assembling the parts;
determines the ease of the assembly
process on the shop floor, determines the
cost of creating assembly
How much planning ahead should be considered before beginning creating an assembly?
The more the better
Assembly Tree
Problems
 ME 252 Geometric Modeling
Spring Semester 2016

Tolerances

Teaching Material is adapted from Prof. Ibrahim Zeid,

Mastering of SolidWorks, Northeastern University - USA
Chapter Objectives
 Variability is an inherent characteristic of manufacturing and it
comes from machine, machinist skill, and machine tool
 Tolerance is the amount of variability in dimensions resulting
from manufacturing a part design
 This chapter aims to teach and train the concept of geometric
dimensioning and tolerancing

 Standardize Design Communication

 Communicate Design Intent
 Calculate Worst Case Assembly
Scenario
 Ensure Effective Inspection
Chapter Organization
 To give an overview of the following concepts

 Types of Dimensioning
 Concepts of Conventional and Geometric Tolerancing
 ASME Tolerance Rules
 Tolerancing Tapers
 Limits of Dimensions
 Tolerance Accumulation
 Statistical Tolerancing
Chapter Organization
 To give an overview of the following concepts

 True Position
 Geometric Tolerancing
 Datum Target Symbol
 Tolerance Interpretation
 Tolerance Analysis
 SolidWorks Tolerance Analysis
 Type of Tolerancing

 The two basic types of tolerancing are:

 Conventional tolerances control the

part size by its dimensions, e.g. part
width and height etc.
 Geometric tolerances control the
form of the part. For example,
control the relation between part
edges i.e. parallel, perpendicular
and angular etc.
Tolerancing Concepts
 Both conventional and geometric tolerances use
some basic concepts that are critical to their
effective use
 Size of a feature (dimension)
 Shaft and hole fitting
 Tolerance zone
 Hole or shaft based reference system
 Limits of dimensions
 Unilateral tolerances (min or max)
 Bilateral Tolerance (min and max)
 Symmetric Tolerance (min and max equidistant from
target)
 Material Condition (minimum and maximum material
conditions)
 Datum
 Datum Target
Tolerancing Concepts

Nominal size Basic size

 ASME tolerance Rules
 To express tolerances correctly you need to
 limit the dimensions
 exhibit plus and minus magnitude
 include notes
 mention tolerances in the title box
ASME tolerance Rules

Limit dimensioning +/- dimensioning

Tolerance note Title block

ASME tolerance Rules

Use a single zero Use same # of dec.

Use same # of dec. Drop zeros

ASME tolerance Rules

Use many zeros Use same # of dec.

Use same # of dec. Keep zeros

Tolerancing Tapers
 Two types of tapers i.e. conical and flat
 Tolerancing of taper diameters and length highly
depend on its functionality
Tolerancing Tapers
Tolerancing Tapers
Limits of Dimensions
 Limits of hole and shaft dimensions is what the
machinist try to achieve
 Need to standardize tolerances and use them to
calculate the limits. ANSI and ISO have standardized the
tolerances in terms of fits of three kinds:

 Clearance
 Transition
 Interference
 Each fit has standard tolerance associated with it which
is specific to the target size
ISO Standards
Clearance, Transition and Interference Fits

d h min  d
d h max  d  h

d s max  d  a
d s min  d  a  s
Use Appendix A to calculate Hole and
Shaft Limits for a given Basic Size d
 Use the type of fit (clearance, transition, or interference) to select the
appropriate table (Table A.1 for clearance, Table A.2 for transition, or
Table A.3 for interference). Then:

dhmin = d + small value in Hole column (always 0)

dhmax = d + large value in Hole column
dsmax = d + large algebraic value in Shaft column
dsmin = d + small algebraic value in Shaft column
 Using the tables:

d h min  d
d h max  d  h

d s max  d  a
d s min  d  a  s
Example
 Identify the type of fits and calculate manually the limits
and tolerance zones for the following fits (a) RC5 for a basic
size of 5.0000 in, (b) LT3 for a basic size of 3.0000 in, (c)
FN4 for a basic size of 6.0000 in.
Fit: RC5 Name: Clearance Fit Fit: LT3 Name: Transition Fit
Basic size: 5.0000 in (+2.5/0.0)(-2.5/- Basic size:3.0000in (+1.2/0.0)(+0.8/+0.1)
5.1)
h 0.0025 h 0.0012
s 0.0026 s 0.0007
a 0.0025 a -0.0008
dhmin 5.0000 dhmin 3.0000
dhmax 5.0025 dhmax 3.0012
dsmin 4.9949 dsmin 3.0001
dsmax 4.9975 dsmax 3.0008

Fit: FN4 Name: Interference Fit

Basic size: 6.0000 in (+1.6)(+8.0/+7.0)
h 0.0016
s 0.001
a -0.008
dhmin 6.0000
dhmax 6.0016
dsmin 6.007
dsmax 6.008
Tolerance Accumulation

 It’s the chain effect of series of tolerances on the

design. Our goal should be to minimize it
 Comparison of three tolerancing schemes for tolerance
accumulation
Tolerance Accumulation

Chain
Baseline

Direct
Statistical Tolerancing
 Stemming out of the fact that the every manufacturing
process has inherent variability, statistical tolerancing is
a method that assumes that it is least expected that you
would get parts manufactured at the extremes of your
tolerancing limits. (Basis for Six Sigma)
Statistical Tolerancing
Statistical Tolerancing
True Position
 Tolerancing a hole center depends on how we locate it and
locating a hole during design means fixing the true
position
Geometric Tolerances
 Complementing conventional tolerancing, geometric
tolerances control location, form and profile of the
design
 Standardized by ASME Y14.5-1994 [R2004] you need to
specify datums, decide the type of geometric
tolerance and create the details
Geometric Tolerances
Geometric Tolerances
 Datum Target Symbols
 Datums are Designated points, lines or areas of contact on a
part to reference other features
 Use datum targets to define datums
Datum Target Symbols

Point datum Line datum

Area datum Area datum explained

Tolerance Interpretation
 Tolerance defines a zone in space where tolerances
feature exists
 Graphical representation of tolerance features is the
best way to understand them
Tolerance Interpretation
Tolerance Interpretation
Tolerance Interpretation
Tolerance Interpretation
Tolerance Analysis
 Tolerance analysis studies how tolerances effect the
dimensional stack-up between two features
 Tolerance synthesis is the reverse of analysis and studies
the distribution of assembly tolerance among the
individual components of the assembly
 Two methods of tolerance analysis are

 Worst case (arithmetic) method

 Statistical method
Tolerance Analysis
 Worst-case (Arithmetic) method

i N iN
f
T   Ti T  Ti
i 1 i 1 xi
i N iN

Tmin   Ti min Tmax   Ti max

i 1 i 1

iN
f iN
f
Tmin  Ti min Tmax   Ti max
i 1 xi i 1 xi
 Tolerance Analysis
2
i N  f  2
iN
T T 2
T     Ti
i 1  xi 
i
i 1

iN iN

Tmin  T 2
i min
Tmax   i max
T
i 1
2

i 1

2
iN
 f  2  f  2
2
  
iN
Tmin  Ti min Tmax     Ti max
i 1  xi 
i 1  xi 
SolidWorks Tolerance Analysis
 Solid Works TolAnalyst Module helps study the tolerance
stack analysis of designed assemblies
Tutorials Overview
 Tutorials are designed to specify both conventional and geometric
tolerances and performing tolerance stack-up analysis using SolidWorks:

 DimXpert
 TolAnalyst
Tutorial 12.1 Create Conventional
Tolerances
 Various methods to display tolerances on a drawing
Tutorial 12.2 Create
Geometric Tolerances
 Add geometric tolerances
Tutorial 12.3 Define Datum Targets
Tutorial 12.4 Tolerance a Taper
Tutorial 12.5 Perform
Tolerance Stack-up Analysis
 ME 252 Geometric Modeling
Spring Semester 2016

CAD- Standards
Rapid Prototyping

Teaching Material is adapted from M. P. Groover, Teaching Material is adapted from Prof. Ibrahim Zeid,
Fundamentals of Modern Manufacturing Mastering of SolidWorks, Northeastern University - USA
 Data Exchange Standards
• Too many companies involved in modeling and manufacturing
• Easy way for two companies to exchange data is to use same CAD/CAM
software
• Many large manufacturers have indeed put pressure on suppliers to adopt
the same systems as they are using
BUT THIS IS NO SOLUTION
• Solution is the use of some neutral format
• This neutral file should be an internationally agreed standard
 Every CAD package saves information internally in a format that is
best suited for that package. When the user is done, this information
is written to files on the hard drive.
 These proprietary formats can only be read by the specific program
(and version of software), and are virtually useless to other
programs.
 For most modern engineering applications it is necessary to be able
to transfer CAD models between dissimilar computer programs.
 Standard file formats are the best method for storing and
transferring CAD geometries (and other information) between
dissimilar programs.
 Files are mainly stored on disks as ASCII, or binary with a structure
that has been agreed upon by organizations that represent various
interest groups in the CAD/CAM sectors.
 When standard formats are used data should be easily transported
between systems. Although beware, some vendors do not conform
fully to these standards.
Why use standard files?

Universally readable allowing easy data transfer

Generally more dependable than proprietary formats
(better throughout)
 Data Exchange Standards
• Four types of modelling data make up the general description
• These are
– Shape; geometrical and topological data
– Non-shape; shaded images and measuring units of the database
– Design; FEM/FEA
– Manufacturing; tolerance and bill of material
CAD/CAM Data Translators

System 5
System 4 System 3

Neutral
Format

System 1 System 2
 Historical Development of CAD data Exchange

• 1979 – Initial Graphics Exchanges Specification (IGES)

Based on ASCII file format, but IGES file usually take more space than the
associated graphics file
• 1983 – IGES (Ver 2)
Included entities for FEM and electrical system applications
• 1985 – SET (Standard d’Exchange et de Transfert)
Same file format as that of IGES but compact
• 1986 – IGES (Ver 3)
Reduced file size
Efficient file processing
• 1989 – IGES (Ver 4)
• 1990’s – IGES (Ver 5)
• 1996 – IGES (Ver 5.3) Last version
 Problems with IGES
• Unreliable translation, particularly for complex geometry
• No information about the way the model is constructed (No Idea about
history tree)
 The future : STEP
• All the good available data exchange standards were drawn together by
ISO into a single unified standard called Standard for Exchange of Product
Data (STEP- Standard d’Exchange et de Transfert)
• STEP is based upon EXPRESS
• EXPRESS has elements of Pascal, C, and other languages
• It contains constructs for defining data types and structures, but not for
processing data
• EXPRESS describes geometry and other information in a standard,
unambiguous way
 Status of STEP
• STEP has been under development for many years, and will continue for
many more
• Over a dozen STEP parts have been approved as international standards
• Many others are under development
 Other CAD File Formats
• DXF
– de facto standard published by AutoDesk (AutoCAD)
• STL
– 3D file format used as input for Stereolithography (A process that uses
a CAD model to guide a laser through a polymer solution. The laser
hardens the solution within the boundary of the part, one thin layer at
a time, to produce a real, three-dimensional mockup )
• SAT
– solid model file format used by ACIS-based CAD systems (ACIS is a
trademark of Spatial Technology, Boulder, CO; stores wireframes,
surfaces, and solids in a single data structure)
 Other Standards
• Standards for technical documents
• Standards for images
• Internet and Web standards
 RAPID PROTOTYPING
1. Fundamentals of Rapid Prototyping
2. Rapid Prototyping Technologies
3. Applications and Benefits of Rapid
Prototyping
 Rapid Prototyping (RP)
A family of fabrication processes 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
 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 and shortcomings
 RP – Two Basic Categories:
1. Material removal RP - machining, using a
dedicated CNC machine that is available to
the design department on short notice
– Starting material is often wax
– The CNC machines are often small - called
desktop machining
2. Material addition RP - adds layers of material
one at a time to build the solid part from
bottom to top
 Starting Materials in Material
Addition RP
1. Liquid monomers that are cured layer by layer
into solid polymers
2. Powders that are aggregated and bonded
layer by layer
3. Solid sheets that are laminated to create the
solid part
 Addition RP Methods
• In addition to starting material, the various
material addition RP technologies use
different methods of building and adding
layers to create the solid part
– There is a correlation between starting material
and part building techniques
 Steps to Prepare Control
Instructions
1. Geometric modeling - design the component
on a CAD system to define its enclosed
volume
2. Tessellation of the geometric model - CAD
model is converted into a computerized
format that approximates its surfaces by
facets (triangles or polygons)
3. Slicing of the model into layers - computerized
model is sliced into closely-spaced parallel
horizontal layers
 Solid Model to Layers

• (a) Conversion of a solid model of an object

into layers (b) only one layer is shown
 More About Rapid Prototyping
• Alternative names for RP:
– Layer manufacturing
– Direct CAD manufacturing
– Solid freeform fabrication
– Rapid prototyping and manufacturing (RPM)
• RP technologies are being used increasingly to
make production parts and production
tooling, not just prototypes
 Classification of RP Technologies
• The RP classification used here is based on
the form of the starting material:
1. Liquid-based
2. Solid-based
3. Powder-based
 Liquid-Based Rapid Prototyping
Systems
• Starting material is a liquid
• About a dozen RP technologies are in this
category
• Includes the following processes:
– Stereolithography
– Solid ground curing
– Droplet deposition manufacturing
 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 - 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. based on work of
Charles Hull
• More installations than any other RP method
 Stereolithography

• (1) At start of the process, in which the initial layer is added to the
platform; and (2) after several layers have been added so that the
part geometry gradually takes form
 Stereolithography

• Part produced by
stereolithograph
y (photo courtesy
of 3D Systems,
Inc.).
 Facts about STL
• Each layer is 0.076 mm to 0.50 mm (0.003 in
to 0.020 in.) thick
– Thinner layers provide better resolution and more
intricate shapes, but processing time is longer
• Starting materials are liquid monomers
– Polymerization occurs on exposure to UV light
produced by laser scanning beam
• Scanning speeds ~ 500 to 2500 mm/s
 Part Build Time in STL

• Time to complete a single layer

Ai
Ti   Td
vD
where Ti = time to complete layer i; Ai = area of
layer i; v = average scanning speed of the laser
beam at the surface; D = diameter of the “spot
size,” assumed circular; and Td = delay time
between layers to reposition worktable
Part Build Time in STL - continued
• Once the Ti values have been determined
for all layers, then the build cycle time is
ni
Tc   Ti
i 1
where Tc = STL build cycle time; and nl =
number of layers used to approximate the
part
• Time to build a part ranges from one hour
for small parts of simple geometry up to
several dozen hours for complex parts
 Solid Ground Curing (SGC)
Like stereolithography, SGC works by curing a
photosensitive polymer layer by layer to
create a solid model based on CAD geometric
data
• 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
• Hardening takes 2 to 3 s for each layer
 Solid Ground Curing
• (1) Mask
preparation, (2)
applying liquid
photopolymer layer,
(3) mask positioning
and exposure of
layer, (4) uncured
polymer removed
from surface, (5) wax
filling, (6) milling for
flatness and
thickness
 Facts about SGC
• Sequence for each layer takes about 90 seconds
• Time to produce a part by SGC is claimed to be
about eight times faster than other RP systems
• The solid cubic form created in SGC consists of
the solid polymer and wax
• The wax provides support for fragile and
overhanging features of the part during
fabrication
– But can be melted away later to leave the free-
standing part
 Droplet Deposition Manufacturing
(DDM)
Starting material is melted and small droplets are
shot by a nozzle onto previously formed layer
• Droplets cold weld to surface to form a new
layer
• Deposition for each layer controlled by a moving
x-y nozzle whose path is based on a cross
section of a CAD geometric model that is sliced
into layers
• Work materials include wax and thermoplastics
 Solid-Based Rapid Prototyping
Systems
• Starting material is a solid
• Solid-based RP systems include the following
processes:
– Laminated object manufacturing
– Fused deposition modeling
Laminated Object Manufacturing (LOM)
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, plastic,
cellulose, metals, or fiber-reinforced materials
• The sheet is usually supplied with adhesive
backing as rolls that are spooled between two
reels
• After cutting, excess material in the layer remains
in place to support the part during building
Laminated Object Manufacturing
Fused Deposition Modeling (FDM)
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
• Workhead is controlled in 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 0.1 s
• Part is fabricated layer-by-layer from the base
up
 Powder-Based RP Systems
• Starting material is a powder
• Powder-based RP systems include the
following:
– Selective laser sintering
– Three dimensional printing
 Selective Laser Sintering (SLS)
Moving laser beam sinters heat-fusible powders
in areas corresponding to the CAD geometry
model one layer at a time to build the solid
part
• After each layer is completed, a new layer of
loose powders is spread across the surface
• Layer by layer, the powders are gradually
bonded by the laser beam into a 3-D solid
geometry
• In areas not sintered, the powders are loose
and can be poured out of completed part
 Three Dimensional Printing (3DP)
Part is built using an ink-jet printer to eject
adhesive bonding material onto successive
layers of powders
• Binder is deposited in areas corresponding to
the cross sections of part, as determined by
slicing the CAD geometric model into layers
• The binder holds the powders together to
form the solid part, while the unbonded
powders remain loose to be removed later
• To strengthen the part, a sintering step can be
applied to bond the individual powders
 Three Dimensional Printing
• (1) Powder layer is deposited, (2) ink-jet
printing of areas that will become the part,
and (3) piston is lowered for next layer
 RP Applications
• Applications of rapid prototyping can be
classified into three categories:
1. Design
2. Engineering analysis and planning
3. Tooling and manufacturing
 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
 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
– Stress analysis of physical model
– Fabrication of pre-production parts for process planning
and tool design
 Tooling Applications
• Called rapid tool making (RTM) when RP is
used to fabricate production tooling
• Two approaches for tool-making:
1. Indirect RTM method
2. Direct RTM method
 Indirect RTM Method
Pattern is created by RP and the pattern is used
to fabricate the tool
• Examples:
– Patterns for sand casting and investment casting
– Electrodes for EDM
 Direct RTM Method
RP is used to make the tool itself
• Example:
– 3DP to create a die of metal powders followed by
sintering and infiltration to complete the die
 Manufacturing Applications
• 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
 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