Lecture # 02 Rapid Prototyping Techniques

BAHIR DAR UNIVERSITY
BAHIR DAR INSTITUTE OF TECHNOLOGY (BiT)
FACULTY OF MECHANICAL AND INDUSTRIAL
ENGINEERING
Rapid Prototyping & Reverse Engineering
[MEng6123]
Rapid Prototyping Techniques

• They can be categorized by material: photopolymer, thermoplastic, and
adhesives.
• Photopolymer systems start with a liquid resin, which is then
solidified by exposure to a specific wavelength of light.
• Thermoplastic systems begin with a solid material, which is then
melted and fuses upon cooling.
• The adhesive systems use a binder to connect the primary
construction material

• The initial state of material can come in either
• solid, liquid or powder state
• The current range materials include
• paper, polymer, nylon, wax, resins, metals and ceramics.

Liquid Based RP Systems
Solidification of a Liquid Polymer
• These process involve the solidification of a resin via electromagnetic
radiation
• There are different processes in this category
• Stereolithography (SL)
• Liquid Thermal Polymerization (LTP)
• Beam Interference Solidification (BIS)
• Solid Ground Curing (SGC)
• Objet Quadra Process (Objet)
• Holographic Interference Solidification

Stereolithography (SL)
Principle of Operation
• Patented in 1986,
• Started the RP revolution
• Developed by 3D Systems, Inc.
• Most popular RP methods.
• The technique builds 3D models from liquid photosensitive polymers that
solidify when exposed to ultraviolet light.
• Builds plastic parts a layer at a time by tracing a laser beam on the
surface of a vat of liquid photopolymer.
• The liquid photopolymer, quickly solidifies wherever the laser beam strikes
the surface of the liquid

Process Description
• The STL file of the proposed
component is sliced by software.
• Each slice is then hatched on to the
surface of a photosensitive ultraviolet
curable resin with a "swinging" laser.
• When the focused beam of the laser
strikes the surface, the resin will be
cured.
• Then the cured layer will be lowered in
to a vat of resin by one-layer
thickness.
• A recoating blade then lays a thin film
of uncured resin over the surface of
the resin.

Process Description
• Overhanging portions of the model are supported by a lattice that is
automatically generated and incorporated into each layer by the software.
• The model is built on a support lattice to prevent direct adhesion to the
recoating table, thus allowing the model to be removed relatively easily on
completion of the build.
• On completion of the build the model is carefully removed from the
platform and washed in a solvent to remove the uncured resin from the
surface.
• The model is then placed in an ultraviolet oven to harden any uncured
resin.

Advantages
• Good dimensional accuracy - The process is able to maintain the
dimensional accuracy of the built parts to within ± 0.1mm. x
• Good surface finish - Glass-like finishing can be obtained on the top
surfaces of the part although stairs can be found on the side walls and
curve surfaces between build layers
• Unattended building process - The system is very stable. Once
started the process is fully automatic and can be unattended until the
process is completed.
• The process is of high resolution and capable to build parts with
rather complex details

Disadvantages
• Curling and warping - The resin absorb water as time goes by resulting
curling and warping especially in the relatively thin areas
• Relatively high cost - However, it is anticipated that the cost will be coming
down shortly.
• Narrow range of materials - The material available is only photosensitive
resin of which the physical property, in most of the cases, cannot be used
for durability and thermal testing.
• Post curing - The parts in most cases have not been fully cured by the laser
inside the vat. A post curing process is normally required.
• High running and maintenance cost - The cost of the resin and the laser
gun are very expensive. Furthermore, the optical sensor requires periodical
fine-tuning in order to maintain its optimal operating condition, which will be
considerably, expensive.

Application Field
• Prototypes for concept models
• Form-fit for assembly tests and process planning
• Models for investment casting, replacement of the wax pattern;
• Patterns for metal spraying, epoxy moulding and other soft tooling;
• A medical application of the stereolithography in surgery to produce
equipment; design and manufacturing of orthopedic implants

Solid Ground Curing (SGC)
• Developed by Cubital (Israel),
• SGC is something of a hybrid between Stereolithography and laser
printing.
• The machine makes an image of the cross-section of the model on a
glass plate, using similar methods to those employed in a laser printer
• The surface of the liquid photo-polymer is solidified by exposing it to
light from a UV lamp (similar to SL), using the glass plate as a mask
which allows the light through to expose the liquid surface in selected
areas.
• Unlike SLA, SGC cures an entire layer at a time.

Process Description
• First, photosensitive resin is sprayed on the build platform.
• Next, the machine develops a photomask (like a stencil) of
the layer to be built.
• This photomask is printed on a glass plate above the build
platform using an electrostatic process similar to that found
in photocopiers.
• The mask is then exposed to UV light, which only passes
through the transparent portions of the mask to selectively
harden the shape of the current layer.

Process Description

Process Description
• After the layer is cured, the machine vacuums up the excess
liquid resin and sprays wax in its place to support the model
during the build.
• The top surface is milled flat and then the process repeats
to build the next layer.
• SGC machines are quite big and can produce large models

Advantages
• Multiple parts can be positioned within the entire working envelop
resulting high throughput;
• No support structure is required as the wax support the structure in
all directions
• Part complexity does not affect speed, however volume does
• Each layer is fully cured resulting that the dimension is very stable
with no shrinkage effect after the process and requires no post-curing
process
• Capable to build even the most complicated parts without much
difficulty
• Build session can be interrupted and erroneous layer can be erased

Disadvantages
• The process is rather complicate which required skilled people to look
after and unattended operation is not possible;
• The resin consumption is disregard of the size of the cross section of
the parts but only depended on the number of layers resulting that it
is too expensive for parts with small cross-sectional area
• The machine is very large and machining is noisy
• Very few materials available
• High equipment cost made it not easily to be justified.

Application field
• Application field of SGC is similar to SLA and can produce
parts with even more complicated details:
• Form-fit for assembly tests and process planning;
• prototypes for concept models
• models for investment casting, replacement of the wax pattern;
• soft tooling;
• medical application

Solid Based RP Systems
Fused Deposition Modeling (FDM)
Principle Of Operation
• FDM is the second most widely used rapid prototyping technology,
next to stereolithography.
• builds a product up in thin layers of thermoplastic wire-like filaments.

Process Description
• In this technique, filaments of heated thermoplastic are extruded
from a tip that moves in the x-y plane.
• Deposits very thin beads of material onto the build platform to form
the first layer.
• The platform is maintained at a lower temperature, so that the
thermoplastic quickly hardens.
• After the platform lowers, the extrusion head deposits a second layer
upon the first.

Process Description

Process Description
• Supports are built along the way, fastened to the part
either with a second, weaker material or with a perforated
junction
• Support structures are fabricated for overhanging
geometries and are later removed by breaking them away
from the object.
• A water-soluble support material which can simply be
washed away is also available

Advantages
• FDM offers greater strength and a wider range of materials
• Quick and cheap generation of models
• Different colours are possible
• Easy and convenient date building
• There is no worry of possible exposure to toxic chemicals, lasers, or a
liquid polymer bath
• The system does not waste material during or after producing the
model, it does not require clean-up
• Materials can be changed quickly

Disadvantages
• Restricted accuracy due to the shape of the material used: wire of
1,27 mm diameter.
• Supports may be required
• Part strength is weak perpendicular to build axis.
• Temperature fluctuations during production could lead to delamination

Application Field
• Model for operation and functional part testing;
• Design model for assessing a product's final appearance and geometry;
• After assembling the parts, the working of complete products can be evaluated;
• Investment casting and injection moulding.

Laminated Object Manufacturing (LOM)
• In this technique, layers of adhesive-coated sheet material are
bonded together to form a prototype.
• The original material consists of paper laminated with heat-activated
glue and rolled up on spools.

Process Description
• Profiles of object cross sections are cut from paper or other web
material using a laser.
• A focused laser cuts the outline of the first layer into the paper and
then cross-hatches the excess area
• The paper is unwound from a feed roll onto the stack and first bonded
to the previous layer using a heated (laminating) roller which melts a
plastic coating on the bottom side of the paper.
• The profiles are then traced by an optics system that is mounted to an
X-Y stage.

Process Description
• After cutting of the layer is complete, excess paper is cut away to
separate the layer from the web.
• Waste paper is wound on a take-up roll
• The method is self-supporting for overhangs and undercuts.
• Areas of cross sections which are to be removed in the final object
are heavily cross-hatched with the laser to facilitate removal

Process Description

Advantages
• The row materials costs are relatively low;
• The process is much faster than competitive techniques;
• The process produces virtually no internal stress and associated
undesirable deformation
• LOM Slice possesses the robust capacity of dealing with imperfect
STL files, created with discontinuities, in which the surfaces of STL
objects are not closed completely
• Best suited for building large parts

Disadvantages
• The stability of the objects is limited by the bonding strength of the
glued layers;
• As the procedure is not well suited for manufacturing parts with thin
walls in the z-direction, the application range is approximately
restricted to complex parts
• Hollow parts, like bottles, cannot be built.

Application Field
• LOM objects are used as precise patterns for secondary tooling
processes such as rubber moulding, sand casting and direct investment
casting
• LOM objects can be used to make spray metal moulds for prototype
injection moulding
• LOM's geometrical stability, inherent precision and high resolution
lends itself to the plaster casting process.
• The durability and rigidity of LOM objects make them suitable for low
to medium volume vacuum forming of thin plastic components
• LOM objects can be used also for limited testing and as visual models.

Multi jet Modelling (MJM)/ Thermo Jet Modeler
• Phase change inkjets also called the Thermo Jet Modeler
• Utilizes several hundred nozzles.

Multi jet Modelling (MJM)
Process Description
• The completed CAD solid model is transferred to a STL file, ready for
the build process.
• Parts are built by an innovative process that uses a MultiJet Modelling
(MJM) head to apply a thermo polymer material in three dimensions.
• The print head comprises multiple jets that build the model layer by
layer.

Advantages
• Lower purchasing costs,
• Cheaper to construct
• Better speed of fabrication (the fastest of all RP methods)
• Low materials cost.
• Recently colour output has also become available.

Disadvantages
• Limitations on resolution, surface finish, part fragility and available
materials.
• Models constructed using this method are weak and can easily be
damaged and distorted.
• Some rapid prints need post-processing, either for design integrity
or aesthetic appearance. (such as sanding, painting,…)
• Completed models are initially fragile and require dipping into
molten wax or an epoxy which introduces durability.

Application Field
• To create ceramic moulds for metal casting.
• To print metal parts directly
• New efforts are directed at making structural ceramic parts and
parts for medical application within the human body.
Injection moulding tools; Ceramic mould and an orthopaedic knee casting poured into a similar mould;. Colour-
coded objects, such as this model of a compressor.

Powder based RP Systems
Selective Laser Sintering (SLS)
• CAD files are transferred to the system, where they are sliced and
drawn, one cross-section at a time, by applying the laser beam to a thin
layer of powder.
• The laser beam fuses the powder particles to form a solid mass that
matches the CAD design.
• As each layer is drawn, the prototypes take shape within the system.

Process Description
• Uses a laser beam to selectively fuse
powdered materials, such as nylon,
elastomer, and metal, into a solid object.
• Parts are built upon a platform which sits
just below the surface in a bin of the heat-
fusible powder.
• A laser traces the pattern of the first
layer, sintering it together.
• The platform is lowered by the height of
the next layer and powder is reapplied.
• This process continues until the part is
complete.
• Excess powder in each layer helps to
support the part during the build.

Process Description
• SLS models can be made in wax, sand or steel powder as well as nylon
• Materials most often used in selective laser sintering are
polycarbonate and nylon. For polycarbonates, densities of 75-92% of
that of the standard injection-moulded material can be obtained; for
nylon even better values, 87-93%, have been realized.
• Another material that is well suited for the process is investment
casting wax. This allows the direct construction of wax patterns for
foundry use.
• The SLS process provides the most functional rapid prototype
available

Advantages
• Capable of producing the toughest part compared with other
process
• Large variety of material can be used, including most engineering
plastic, wax, metal, ceramic, etc.
• Parts can be produced in short time, normally at a rate of up to 1
inch per hour
• No post curing of parts is required
• During the building process, the part is fully supported by the
powder and no additional support is required.
• Parts can be built on top of others

Disadvantages
• The powder material requires to heat up to the temperature below the
melting point before the building process, which takes about 2 hours.
• After building the parts, it also takes 5 to 10 hours to cool down
before removing the parts from the powder cylinder.
• The smoothness of the surface is restricted to the size of the powder
particles and the laser spot resulting that the surface of the part is
always porous.
• Smooth surface can only be obtained by post processing
• The process chamber requires continuous supply of nitrogen to provide
a safe environment for the sintering process to be taken place
resulting expensive running cost of the process.
• Toxic gases will be generated from the process, which leads to an
environmental issue.

Application Field
• Considering the density results just mentioned, selective laser
sintering is particularly suited to build fully functional prototypes in
polycarbonates and/or nylons, that closely approximate the mechanical
properties found in the final (i.e., injection-moulded) products.
• Such models can be tested before any capital outlay for the
construction of injection moulds becomes necessary

Three Dimensional Printing (3DP)
• Rely on squirting a build material in a liquid or melted state, which
cools or otherwise hardens to form a solid on impact.

Process Description
• uses a single jet each for a plastic
build material and a wax-like support
material, which are held in a melted
liquid state in reservoirs

Process Description
• The liquids are fed to individual jetting
heads which squirt tiny droplets of the
materials as they are moved in X-Y plane
in the required pattern to form a layer of
the object.
• The materials harden by rapidly dropping
in temperature as they are deposited.
• After an entire layer of the object is
formed by jetting, a milling head is
passed over the layer to make it a
uniform thickness.
• The process is repeated to form the
entire object.
• After the object is completed, the wax
support material is either melted or
dissolved away.

Advantages
• The most outstanding characteristic of this system is the ability to
produce extremely fine resolution and surface finishes, essentially
equivalent to CNC machines.

Disadvantages
• Slow for large objects.
• The milling head creates noise
• Materials selection is very limited. All thermal phase change inkjets
have material limitations and make fragile parts.

Application Field
• The applications range from concept models to precise casting
patterns for industry and the arts, particularly jewellery.

Laser Engineered Net Shaping (LENS)
• A high-power laser is used to melt
metal powder supplied coaxially to the
focus of the laser beam through a
deposition head
• The laser beam typically travels
through the centre of the head and is
focused to a small spot by one or more
lenses.
• The XY table is moved in raster
fashion to fabricate each layer of the
object.
• The head is moved up vertically as
each layer is completed

• Metal powders are delivered and
distributed around the circumference
of the head either by gravity, or by
using a pressurized carrier gas.
• An inert shroud gas is often used to
shield the melt pool from atmospheric
oxygen for better control of
properties, and to promote layer to
layer adhesion by providing better
surface wetting

• A variety of materials can be used such as stainless steel, Inconel, copper,
aluminium etc.
• Of particular interest are reactive materials such as titanium.
• Materials composition can be changed dynamically and continuously, leading to
objects with properties that might be mutually exclusive using classical
fabrication methods.
• The strength of the process lies in the ability to fabricate fully dense metal
parts with good metallurgical properties at reasonable speeds.
• Objects fabricated are near net shape, but generally will require finish
machining.
• They have good grain structure, and have properties similar to, or even better
than the intrinsic materials.

Three-dimensional welding
• In these processes, metallic powder or wire is fed directly into the
focal point of an energy beam to create a molten pool with the aid of a
robotic multi-axis system.
• Lasers and electron beams are commonly used as a directed energy
source during the process.
• This process not only allows the production of new metal components
but is also used to repair parts, when the damaged portion is
reconstructed selectively.
• Another advantage is the capability of improving tribological
performance of any engineered products and the ability to add
coatings to existing surfaces.

ASTM Classification
• According to the ASTM F2792 2015 standards on Additive Manufacturing
Technologies, the existing additive manufacturing technologies are
classified as follows
1. Material extrusion
2. Powder bed fusion
3. Vat photopolymerization
4. Material jetting
5. Binder jetting
6. Sheet lamination
7. Directed energy deposition

• Material extrusion—process that creates layers by mechanically
extruding molten thermoplastic material onto a substrate.
ASTM Classification

• Powder bed fusion—these techniques use an energy beam, either a
laser or electron beam, to melt selectively a powder bed.
ASTM Classification

• Vat photopolymerization—an ultraviolet laser is used to polymerize
selectively a UV curable photosensitive resin to create a layer of
solidified material. Layers are subsequently cured until the part is
complete.
ASTM Classification

• Material jetting—processes that directly deposit wax or photopolymer
droplets onto a substrate via drop-on-demand ink jetting.
ASTM Classification

• Binder jetting—process that deposits a stream of particles of a binder
material over the surface of a powder bed, joining particles together
where the object is to be formed.
ASTM Classification

• Sheet lamination—layers of adhesive-coated paper, plastic or metal
laminates are successively glued together and then cut to shape with a
knife or laser cutter.
ASTM Classification

• Directed energy deposition—metallic powder or wire is fed directly
into the focal point of an energy beam to create a molten pool.
ASTM Classification

Lecture # 02 Rapid Prototyping Techniques

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