Scribd
Upload
27 views

Digital Modeling and Rapid Prototyping

Digital modeling and rapid prototyping allow designers to create physical 3D models from digital files. The document discusses different digital modeling techniques like 3D printing, laser cutting, and CNC machining. It also covers rapid prototyping methods such as stereolithography, fused deposition modeling, and laminated object manufacturing. Rapid prototyping helps speed up the design process by creating prototypes faster than traditional methods. Designers can validate designs by building and testing physical models in hours or days instead of weeks. While rapid prototyping provides benefits, it also faces challenges like material limitations and accuracy issues.

Uploaded by

Anonymous mzF3JvyTJs
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
27 views

Digital Modeling and Rapid Prototyping

Digital modeling and rapid prototyping allow designers to create physical 3D models from digital files. The document discusses different digital modeling techniques like 3D printing, laser cutting, and CNC machining. It also covers rapid prototyping methods such as stereolithography, fused deposition modeling, and laminated object manufacturing. Rapid prototyping helps speed up the design process by creating prototypes faster than traditional methods. Designers can validate designs by building and testing physical models in hours or days instead of weeks. While rapid prototyping provides benefits, it also faces challenges like material limitations and accuracy issues.

Uploaded by

Anonymous mzF3JvyTJs
Copyright
© © All Rights Reserved
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
You are on page 1/ 28

Digital Modeling

and
Rapid Prototyping
PROJECT SUBMITTED BY:
MURTAZA LOKHANDWALA
MUSTAFA PARDAWALA

Digital modeling
Digital modeling is a process that joins design with the

construction/production through use of 3D modeling


software and additive and subtractive manufacturing
processes.
These tools allow designers to produce digitally
materiality, which is something greater than of an image
on a screen, and actually tests the accuracy of the
software and computer lines.
Architects can propose complex surfaces, where the
properties of material should put the design

Machines for digital modeling:


1. COMPUTER NUMERICAL CONTROL (CNC)
2. LASER CUTTER
3. 3-D PRINTERS

MACHINES for fabrications


CNC
CNC router: CNC stands for

computer numerical control.


Through a computer controller
, g-codes are read which
represent specific CNC
functions in alphabetical
format.
The g-codes drive a machine
tool, a powered mechanical
device used to fabricate
components
CNC machines are specifically
successful in milling materials
such as plywood, foam boards,
and steels at a fast speed.

LASER CUTTER
Used to cut materials such as chip board,

matte board, felt, wood, and acrylic up to


3/8" (1cm) thickness.
The laser cutter is often bundled with a

driver software which interprets vector


drawings produced by any number of
CAD software platforms.
It is able to modulate the speed of the

laser head, as well as the intensity and


resolution of the laser beam.
Objects cut out of materials can be used

in the fabrication of physical models .

3D PRINTERS
Use a variety of methods and

technology to assemble physical


versions of digital objects.
A thin layer of an object is
constructed at a time and then
building another layer of the
same object immediately on top
of the prior one.
Uses a 3-axis robotic system
that extrudes material, one thin
layer at a time and progressively
builds up a shape.
. Examples of machines are:
Dimension 768 and the Ultimaker.

Rapid Prototyping (RP)


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

RAPID PROTOTYPING
Technology which considerably speeds the

iterative product development process


It is a group of techniques used to quickly
fabricate a scale model of a physical part or
assembly using a 3D computer aided
design(CAD).

Fig: a) Examples of parts made by rapid prototyping b) Stereolithography model of cellular phone

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 art and assess its merits
and shortcomings.

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 RAPID
PROTOTYPING
Rapid prototyping is classified to 3-major

groups:
a)

Subtractive ( Removal of material )

b)

Additive ( Adding of material )

c)

Virtual ( Advanced computer base


visualization)

Subtractive Process
Subtractive process use computer based Prototype

technology to speed the process

Essential Technologies for subtractive prototyping :


Computer based drafting packages ( 3-D

representation of parts)

Interpretation software (Translation of cad file to

manufacturing software)

Manufacturing Software (Planning Machining

operations)

Computer-Numerical Control Machinery

SUBTRACTIVE PROTOTYPING

ADDITIVE PROTOTYPING
Additive prototyping refers to a

class of manufacturing processes,


in which a part is built by adding
layers of material upon one
another.
Theydo not require custom
tooling or planned tool
movements.
The part is constructed directly
from a digital 3-D model created
through Computer Aided Design
(CAD) software.
Advantages: speed, part
complexity, material types, lowvolume production.

Virtual prototyping
Virtual prototyping is the modeling and

simulation of all aspects of a prototype, i.e.


mechanical design, kinematics, dynamics,
and controls accompanied by a realistic
visualization.

Realizing the best design in the shortest

lead-time of complex products/processes

Allows the exotic, unconventional designs be

prototyped, rapidly and cost-effectively

CLASSIFICATION OF RP
TECHNOLOGIES
LIQUID BASED
SOLID BASED
POWDER BASED

1. Liquid-Based Rapid
Prototyping Systems
Starting material is a liquid
About a dozen RP technologies are in this

category
Includes the following processes:
A. Stereolithography
B. Solid ground curing
C. Droplet deposition manufacturing

A. Stereolithiography
Here a photosensitive liquid resin

which forms a solid polymer when


exposed to ultraviolet light is
used.
the reaction only takes place near
the surface and voxels of solid
polymeric resin are formed.
machine consists of a build
platform (substrate), which is
mounted in a vat of resin and a UV
laser.
Here the first layer is scanned, the
platform is then lowered and held
at that position for the proper
settlement of the liquid polymer.
After this a new layer is scanned
and the process is continued.

B. 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


Figure 34.4 SGC
steps for each
layer: (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.

C. 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

2. Solid-Based Rapid
Prototyping Systems
Starting material is a solid
Solid-based RP systems include the following

processes:
1. Laminated object manufacturing
2. Fused deposition modeling

Laminated Object
Manufacturing
Consists of layers which are adhesively

bonded to one another

Uses layer of paper or plastic sheets with

heat activated glue on one side of the


product parts

Excess material to be removed manually


Simplified by preparing the laser to burn

perforations in cross-sectional pattern


LOM uses sheets as thin as 0.05mm

Compressed paper has appearance and

strength of soft wood , and often mistaken


for elaborate wood carvings

Fused Deposition Modeling


Fused Deposition Modeling
(FDM) is process in which a
movable nozzle deposits threads
of molten polymeric material.
The build material is heated
slightly above its melting
temperature so that it solidifies
within a very short time and
after extrusion it welds to the
previous layer.
Recent FDM systems
include two nozzles, one for part
material and other for support
material.
Support material is relatively of
poor quality and can be broken
easily once the complete part is
deposited and removed.

Fig : (a)Fused-deposition-modeling process.


(b)The FDM 5000, a fused-decompositionmodeling-machine.

Applications
Designers are able to confirm their design by building a real

physical model in minimum time using RP.


Existence of part allows certain engineering analysis and

planning activities to be accomplished that would be more


difficult without the physical entity.
Also applicable in various industries such as aerospace,

automotive, biomedical, electronics etc.

Advantages
CAD data files can be manufactured in hours.
Tool for visualization and concept verification.
Prototype used in subsequent manufacturing

operations to obtain final part

Tooling for manufacturing operations can be

produced

Decreasing delivery time.


To increase effective communication.

Problems with Rapid Prototyping


Material issues
High prices of the equipments
Forming accuracy and quality issues
The problem of software
A single feature
During part deposition generally two

types of errors are observed:


1. Curing errors: are due to over or under
curing with respect to the curing line.
2. Control errors: due to variation layer
thickness and scan position.

Thank you

You might also like