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Rapid Prototyping Basics

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PRANJAL BHARGAVA
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14 views

Rapid Prototyping Basics

Uploaded by

PRANJAL BHARGAVA
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
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CONTENTS

• Fundamental of Automated Process


i. Subtractive
ii. Additive
iii. Formative
• Process Chain

MTE/V SEMESTER/AMT/MTE 4009 1


1.Fundamental Automated Process

• There are three fundamental fabrication processes:


1. Subtractive
2. Additive
3. Formative

MTE/V SEMESTER/AMT/MTE 4009 2


• Subtractive Process:
i. In this process, a single block of
material is taken which is larger than
final size of the desired object.
ii. Portions of the material are removed
until the desired shape is reached.
iii. Ex: CNC, Milling,etc.
MTE/V SEMESTER/AMT/MTE 4009 3
• Additive Process
i. It is exact opposite of the subtractive
process.
ii. In this the end product is larger than the
initial material.
iii. Ex: SLS, LOM etc.

MTE/V SEMESTER/AMT/MTE 4009 4


• Formative Process
i. Mechanical forces are applied on a
material so as to form it into desired
shape.
ii. Ex: Bending, Forging etc.

MTE/V SEMESTER/AMT/MTE 4009 5


2. Process Chain

• There are eight key steps in the additive process chain:


i. Conceptualization and CAD
ii. Conversion to STL
iii. Transfer and manipulation of STL file on AM machine
iv. Machine setup
v. Build
vi. Part removal and clean-up
vii. Post-processing of part
viii. Application
MTE/V SEMESTER/AMT/MTE 4009 6
MTE/V SEMESTER/AMT/MTE 4009 Fig.: The eight stages of the AM process 7
• Step 1: Conceptualization and CAD
Conceptualization can take many forms, from textual and narrative
descriptions to sketches and representative models.

MTE/V SEMESTER/AMT/MTE 4009 8


• Step 2: Conversion to STL file
The STL file format approximates the surfaces
of models using tiny triangles.
STL files for curved paths can be very large.
The process of converting to STL is automatic
within most CAD systems, but there is a
possibility of errors occurring during this
phase.
MTE/V SEMESTER/AMT/MTE 4009 9
• Step 3: Transfer to AM Machine and STL File Manipulation
Once the STL file has been created, it can be sent directly to the target AM machine.
Tasks that need to be done before going for printing:
The first task would be to verify that the part is correct.
The user may wish to reposition the part or even change the orientation to allow it to be built at a
specific location within the machine.
Applications may also require that the part be identified in some way and some software tools have
been developed to add text and simple features to STL formatted data for this purpose.

MTE/V SEMESTER/AMT/MTE 4009 10


• Step 4: Machine Setup
All AM machines will have at least some setup parameters that are specific to that
machine or process.
Some machines may have numerous setup operations.(Other machines are
designed to run with a variety of materials and may also have some parameters
that require optimization to suit the type of part that is to be built)

MTE/V SEMESTER/AMT/MTE 4009 11


• Step 5: Build
Once the steps are completed, the process switches to the computer-
controlled building phase.
All machines will repeat the process until either the build is complete or
there is no source material remaining.

MTE/V SEMESTER/AMT/MTE 4009 12


• Step 6: Removal and Clean up
In this stage the output from the AM machine should be ready for use.
The part must be either separated from a build platform on which the part was
produced or removed from excess build material surrounding the part.
The clean up stage may also be considered as the initial part of the post-
processing stage.

MTE/V SEMESTER/AMT/MTE 4009 13


• Step 7: Post-process
Post-processing refers to the (usually manual) stages of finishing the parts for
application purposes.
This may involve abrasive finishing, like polishing and sandpapering, or
application of coatings.

MTE/V SEMESTER/AMT/MTE 4009 14


• Step 8: Application
Following post-processing, parts are ready for use.

MTE/V SEMESTER/AMT/MTE 4009 15

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