LJMU HD in AME

Module Name with Code -Automotive materials and

manufacturing processes -5501ICBTAE
Semester - Semester 3
Batch Number -
Lecturer Name -
Center Name -

LJMU Higher Diploma 1

Content

• Rapid prototyping

LJMU Higher Diploma 2

 INTRODUCTION
WHAT IS A PROTOTYPE?
 A prototype is a draft version or an approximation of a final product.

 Prototypes are developed for several reasons:

• to identify possible problems.
• to confirm the suitability of a design prior to starting mass production.
• Provides a scale model to conduct tests and verify performance.

• Some prototypes are used as market research and promotional tools.

• Most importantly, it is cheaper to manufacture, test and make

changes to a prototype than it is to a final product.
 Rapid prototyping
Rapid prototyping is a group of techniques used to quickly fabricate
a scale model of a physical part or assembly using three-
dimensional computer aided design (CAD) data. Construction of
the part or assembly is usually done using 3D printing or "additive
layer manufacturing" technology.
 The first rapid prototyping method, called stereo lithography, was
developed in the late 1980s, but more sophisticated techniques are
available today.

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 Rapid prototyping
 The term “rapid” is relative. Some prototypes may take hours or
even days to build.

 Rapid prototyping systems are additive manufacturing processes that

work on the basic principle of producing a 3D part by building and
stacking multiple 2D layers together.

 Most common types of rapid prototyping systems:

 SLA (Stereo Lithography)
 SLS (Selective Laser Sintering)
 LOM (Laminate Object Manufacturing)
 FDM (Fused Deposition Modeling).

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 Different technologies use different materials to produce the parts.
 Rapid prototyping
 There are many different RP processes, but the basic operating
principles are very similar.

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 Basic operating principles of rp
 Building computer model

 Model is build by CAD/CAM system.

 Model must be defined as enclosed volume or solid.

 Converting model into STL file format

 Stereo Lithography (STL) file is a standard format to describe CAD

geometry used in RP system.

 STL file approximates the surfaces of the model by polygons.

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  Fabricating the model
 Building model layer by layer.

 Forming a 3D model by solidification of liquid/powder.

 Removing support structure and cleaning

 After building Drain out extra material.

 Cut out the prototype.

 Cut out unnecessary support material.

 Post processing 10

 Includes surface finishing and other applications.

 Applications of rp

 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

 Wind tunnel testing of streamline shapes

 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
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

2 )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
 ADVANTAGES OF RAPID PROTOTYPING
 Process is Fast and accurate.

 Superior Quality surface finish is obtained.

 Separate material can be used for component and support .

 No need to design jigs and fixtures.

 No need of mould or other tools.

 Post processing include only finishing and cleaning.

 Harder materials can be easily used .

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 Minimum material wastage.
 Reduces product development time considerably.
 Limitations of rp

 Some times staircase effect is observed.

 Many times component get distorted.

 Limited range of materials.

 Cost of operating.
 Stereo lithography files
 The stereo lithography file format, known as STL (Standard Tessellation
Language), is the current industry standard data interface for rapid prototyping
and manufacturing.
 Before a 3D model is sent to a rapid prototype machine, it must be converted to
this format.

 From a user standpoint, the process typically requires only exporting or saving the
model as an STL file. Some software packages, however, allow the userin to define
some specific parameters.

 The STL file format defines the geometry of a model as a single mesh of triangles.

Information about color, textures, materials, and other properties of the object
are ignored in the STL file.
 When a solid model is converted into an STL file, all features are consolidated
into one geometric figure. The resulting STL file does not allow individual
features created with the parametric modeling application to be edited.

LJMU Higher Diploma 16

Inventor .Stl save procedure
Remember to
use “Save Copy
As” not “Save.”

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Select .stl as file type
 Stereo lithography files
 The process of approximating the actual surfaces of the object with a
closed mesh of triangles is known as Tessellation.

 When the tessellated STL file is sent to the rapid prototype machine, the
model is sliced into multiple horizontal layers that are later reproduced
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physically by the device.

 Why .Stl file format?
 The STL files translate the part geometry from a CAD system to the RP
machine.

 Universal file format that every system needs to be able to produce so that
an RP machine can process model.

 Slicing a part is easier compared to other methods such as B-rep

(boundary representation) and CSG (constructive solid geometry)
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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

 Easy to machine

 Can be melted and re-solidified

 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
 Classification of rp technologies
 There are various ways to classify the RP techniques that have
currently bee developed

 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 Mostly resins and polymers.

 About a dozen RP technologies are in this category

 Includes the following processes:

 Stereo lithography

 Solid ground curing

 Droplet deposition manufacturing

 Solid-based rapid prototyping
systems

 Starting material is a solid wood, plastic, metal sheets etc.

 Solid-based RP systems include the following processes:

 Laminated object manufacturing

 Fused deposition modeling

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Powder-based rp systems

 Starting material is a powder of hard materials like

 Powder-based RP systems include the following:

 Selective laser sintering

 Three dimensional printing

 Laser engineered and Net shaping

 Stereo lithography (sla)
 Works based on the principle of
curing liquid photomer into specific
shape
Focusing system Rotating mirror
High-speed
 A vat which can be lowered and raised stepper motors
filled with photocurable liquid
He-Cd Laser
acrylate polymer

 Laser generating U-V beam is focused UV beam

in x-y directions
 The beam cures the portion of photo

Sensor system
for resin depth
polymer and produces a solid body
Liquid resin

 This process is repeated till the level b Part

is reached as shown in the figure
Support structures
 Now the plat form is lowered by
distance ab Platform

He-Ne Laser
Elevation control
 Then another portion of the cylinder
is shaped till the portion is reached
 Stereo lithography (sla)
 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

 Accuracy(mm) - 0.01- 0.2(SLA)

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SLA: companies and applications
Companies that develop and sell SLA machines:
1. 3D Systems™ Inc. (www.3Dsystems.com)
2. Aaroflex Inc (www.aaroflex.com)

Shower head

Automobile Manifold
(Rover)
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Stereo lithography (sla) parts

part produced by stereolithography

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Laminated object manufacturing (lom)
3
0 Laminated object manufacturing
 Laminated Object Manufacturing is a relatively low cost rapid prototyping technology

 where thin slices of material (usually paper or wood) are successively glued together
to form a 3D shape.

 The process uses two rollers to control the supply of paper with heat-activated glue
to a building platform.

 When new paper is in position, it is flattened and added to the previously created
layers using a heated roller.

 The shape of the new layer is traced and cut by a blade or a laser. When the layer
is complete, the building platform descends and new paper is supplied.

 When the paper is in position, the platform moves back up so the new layer can be
glued to the existing stack, and the process repeats.
 LOM: companies, applications
Original technology developed by Helisys Inc.; Helisys acquired by
Corum.

1. Cubic Technologies Inc [www.cubictechnologies.com]

2.KIRA Corp, Japan [www.kiracorp.co.jp]

[source: Corum Inc] [source: KIRA corporation]

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Laminated object manufacturing (lom)

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3

Laminated object manufacturing facts

 Layer thickness(mm) - 0.1 - 1(LOM.);

 Starting sheet stock includes paper, plastic, cellulose, metals, or

fiber-reinforced materials

 Accuracy(mm) - 0.1 - 0.2(LOM);

 Fused deposition modeling
• A gantry robot controlled extruder
head moves in two principle
directions over a table

• Table can be raised or lowered as

needed

• -Thermo plastic or wax filament

is extruded through the small
orifice of heated die

• Initial layer placed on a foam

foundation with a constant rate

• Extruder head follows a

predetermined path from the file

• After first layer the table is

lowered and subsequent layers are Fig : (a)Fused-deposition-modeling process3.5
formed (b)The FDM5000, a fused-decomposition-
modeling-machine.
FDM: companies and applications
FDM™ is a patented technology of Stratasys™ Inc.

Gear assembly
Toy design using FDM models of different colors

Monkey Cinquefoil 36
Designed by Prof Carlo Sequin, UC Berkeley
5 monkey-saddles closed into a single edged toroidal ring
3
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Fused deposition modeling

(fdm)
3
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Fused deposition modeling (fdm)

 Materials:
ABS,
Polycarbonate (PC), Polyphenylsulfonen (PPSF)
Metals

 Layer thickness(mm) - ~0.05(FDM);

 Accuracy(mm) - 0.127 - 0.254(FDM);

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Selective laser sintering (sls)
 Uses a high power laser and powdered materials.

 A wide variety of materials can be used, ranging from thermoplastic

polymers, such as nylon and polystyrene, to some metals.

 3D parts are produced by fusing a thin slice of the powdered material

onto the layers below it.

 The surfaces of SLS prototypes are not as smooth as those produced

by SLA processes.

 SLS parts are sufficiently strong and resistant for many functional
tests.
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Selective laser sintering (sls)

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Selective laser sintering (sls)
 The powdered material is kept on a delivery platform and supplied to the
building area by a roller.

 For each layer, a laser traces the corresponding shape of the part on the
surface of the building area, by heating the powder until it melts, fusing it with
the layer below it.

 The platform containing the part lowers one layer thickness and the platform
supplying the material elevates, providing more material to the system.

 The roller moves the new material to the building platform, leveling the surface,
and the process repeats.

 Some SLS prototype machines use two delivery platforms, one on each side of
the building platform, for efficiency, so the roller can supply material to the
building platform in both directions.
SLS: companies and applications
First commercialized by Prof Carl Deckard (UT Austin)
Marketed by DTM Corp.
DTM acquired by 3Dsystems Inc.

1. 3D Systems™ Inc. (www.3Dsystems.com)

2. EOS GmbH, Munich, Germany.

Plastic parts using SLS Metal mold using SLS, injection molded parts

[both examples, source: DTM inc.]

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3D printing
Technology invented at MIT in1994, Part constructed with starch
powder
1. Layer of powder spread on platform
2.Ink-jet printer head deposits drops of water/glue* on part cross-
section
3. Table lowered by layer thickness
4. New layer of powder deposited above previous layer
5. Repeat steps 2-4 till part is built
6. Shake powder to get part
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3

Materials used:
Starch, plaster-ceramic powder, metal powder
Multi-colored water can be used to make arbitrary colored parts (same as
ink-jet
Printing)
 Applications of 3DP
 CAD-Casting metal parts. A ceramic shell with integral cores can
be fabricated directly from the CAD model
 Direct metal parts. It is adaptable to a variety of material
systems, allowing the production of metallic/ceramic parts with
novel composition
 Prototypes with colours and elastic feature
3D Printing: companies, applications

1. Z-corporation [www.zcorp.com]
2. Soligen [www.soligen.com]

Engine manifold for GM racing car

Cast after Direct Shell Production Casting
[source: www.soligen.com]
 Recommended readings

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