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Rapid Prototyping
October 03, 10, 2011
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Introduction
Product Design and Development Phase
Engineering Activities 3 distinct phases
Design Phase Prototyping Phase
Manufacturing Phase
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Major obstacles for massmanufacturing
Long lead time Shoe industry 6 months
Garment industry 6 months
Car Industry 3-4 years Airspace Industry 4-5 years (Boeing, Airbus)
Indian airspace 10-15 years (India)
Submarine 10-15 years Arjun MBT 25 years
Art to Part: As less as possible
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Why Rapid Prototyping?
Because product designers would like to have aphysical model of a new part or product designrather than just a computer model or line
drawing
Creating a prototype is an integral step in design
A virtual prototype(a computer model of the part
design on a CAD system) may not be sufficient forthe designer to visualize the part adequately
Using RP to make the prototype, the designer canvisually examine and physically feel the part andassess its merits and shortcomings
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Advantages and Disadvantages ofRP
Cost
Accuracy
Materials limited Time
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Introduction
Design Manufacturing
3 types of checks:
Form Check aesthetic, Fitness Check assembly, etc.
Function Check
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Product Design & DevelopmentCycle Block Diagram
Conceptual Design
Preliminary Design
Engineering Analysis
Detailed Design
Set of sketches e.g.styling
Specifications ofthe product
Total Design ActivityDrawings, BOM,Tolerances, etc.
Dimensions, materials,
Factor of safety,Performance Indices
Conceptual Design:Scanning also, as
very rarely the
Design is startedfrom blue
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Block Diagram contd.
Prototyping
Testing (Inspection)
Tooling
Optimization
Parts
Test Reports
Tooling - Molds,Dies, etc.
Release to Manufacture
Iterations, etc.are missingin the block
diagram
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Conventional Prototyping
Prototype is the first or original example of anartifact
that has been designed
that is a model or a preliminary version
that needs to be developed (evolving
model, developed, tested & so on severaliterations)
that will be manufactured on a mass scale
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Prototyping Methods
3 different methods
Manual Prototyping
Virtual Prototyping
Rapid Prototyping 4 aspects Inputs
Methods
Materials Applications Design
Engineering Analysis
Tooling and Manufacturing
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Tooling(A) Material Removal Processes (Subtractive Type)
Traditional Methods
Turning
Shaping, Planing
Drilling, Boring Milling, Hobbing
Broaching, Tapping
Reaming, Grinding
Requires tools and fixtures
Non-traditional Methods: ECM, EDM, USM, EBM, IBM,PAM, LBM, WJM, AJM, etc.
Both processes require tools and are subtractive innature
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Tooling(B) Net Shape or Material Forming Processes
Traditional Methods
Forging
Casting
Deep drawing Bending
Extruding
Die casting
Rolling
Non-traditional Methods: 3D Laser Forming, LaserBending, etc.
Tools are required in the form of moulds or tool anddie
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Tooling(C) Material Addition Processes
Traditional Methods
Welding
Soldering, Brazing
Tools required in the form of holding fixtures Non-traditional Methods:
Rapid Prototyping Processes
SLA, SLS, FDM, LOM, 3DP, BPM, etc
RP processes do not require tools and fixtures
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Rapid Tooling Processes To have multiple copies RT processes
Basically of the type casting, forging, etc. i.e.Formative traditional processes
RT Processes: RT Silicone Molding
Vacuum Casting / Forming
Spray Metal Tooling (TAFA)
Resin Transfer (Epoxy Tool) Molding
Investment Flask Casting
Investment Shell Casting
Special Sand Casting
RT batch size 50-1000, ,10,000 parts replica ofRP processes
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Terminology Rapid Prototyping (RP)
Solid Freeform Fabrication (SFF) Desktop Manufacturing (DTM) Freeform Fabrication (FFF) Direct CAD Manufacturing
Instant Manufacturing Layer Manufacturing Techniques (LMT) Material Deposition Manufacturing Material Addition Manufacturing Material Accretion Manufacturing Generative Processes / Generative Manufacturing
Processes (GMP) Time Compression Technologies (TCT)
Analogous to Laser Printer
As it requires CAD geometryessentially unlike other processes
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Classification Liquid-Based
Solid-Based
Powder-Based
Liquid Based
SLA
SGC
Solid Object Ultraviolet
Laser Plotter (SOUP)
Light Sculpting
Two Laser Beam Plotter
Solid Based
FDMLOM
MJM (Multi Jet Modeling)
Selective Laser Adhesive& Hot Press (SAHP)
Powder Based
SLS
3DPBPM
Multiphase Jet Solidification (MJS)
Direct Shell Production Casting(DSPC)
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RP Processes
Photopolymer
Photopolymer resinsensitive to light
cross linking takes
place Monomer to
Polymer
Thermal
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RP Processes
Controls MaterialsRP
Physical &Chemical
Information
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Historical Perspective1. 3D Maps / Topography (Topographical Maps)
Blanther 1892 used wax
Pareira 1940 cardboard
Zang 1964 transparent plastic sheet
Gaskin 1973
Matsubara 1974 thin layer of powder / refractory particles(graphite) coated with photopolymeric materials (acrylate) his goal to make a casting mold
DiMatteo 1976 sheet metal plates edges smoothened
Nakagawa 1979 blanking dies, press forming dies,injection molding dies
2. Photo sculpture
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RP Methodology1. To create a solid Model
2. Create RP Model
3. Evaluate form, fit & modify solid model
4. Create revised RP Model (Tested for form & fit)
5. Create tooling for functional part
6. Evaluate the part for the function
7. Modify CAD solid model & repeat Steps 1, , 6
8. Finalize the design
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Overview
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Prototyping
Prototyping or model making is one of the important steps to
finalize a product design. It helps in conceptualization of adesign. Before the start of full production a prototype isusually fabricated and tested.
Manual prototyping by a skilled craftsman has been an age-old practice for many centuries.
Second phase of prototyping started around mid - 1970s,when a soft prototype modeled by 3D curves and surfacescould be stressed in virtual environment, simulated andtested with exact material and other properties.
Third and the latest trend of prototyping i.e. RapidPrototyping (RP) by layer-by-layer material deposition,started during early 1980s with the enormous growth inComputer Aided Design and Manufacturing (CAD/ CAM)
technologies.
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Product Fabrication Approaches
Machining
Joining
Forming
LayerDepositionor Rapid
Prototyping
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RP uses layer by layer additive approach to build shapesRP systems use liquid, powder or sheet materials to formphysical objects
[Courtesy: Kai & Fai]
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Basic Principles of Rapid Prototyping
[Courtesy: Kai & Fai]
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Step 1: Solid Modeling and Tessellation
[Courtesy: Zeid]
Surfaces of the
CAD model aretessellated andSTL file is exported
Tessellation is
piecewiseapproximation ofsurfaces of CADmodel by using
series of triangles
S Sli i
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Step 2: Slicing
[Courtesy: Kai & Fai]
After selecting part deposition orientation, tessellated model
is sliced This information is saved in standard formats like SLC or CLI
etc.
S 3
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Step 3
Generation of Laser Scanning Paths or Material DepositionPaths
Deposition of Layers: various technologies for layerdeposition are used
Liquid based : Stereolithography
Powder based : Selective Laser Sintering
Solid based : Fused Deposition Modeling,Laminated Object Manufacturing, etc.
S 4 P P i
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Step 4: Post Processing
Post Curing
Removal of Support Structures
Finishing by Sanding, Polishing or Painting
G li d Ill t ti f D t Fl i RP
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Generalized Illustration of Data Flow in RP
STL (3D)Layer Information, SLC or CLI
3D CAD
3D Reconstruction
2.5D ReconstructionReverse Engineering
3D CAD2D CAD Drawing /Manual Outline /
Lattice Data
Point CloudData
Data acquiredfrom MRI /CT Scan
Geometric Data
Specification of MachineLayer Information
Machine Data Set
Process ParametersMachine Parameters
Auxiliary Geometry, Supports, etc.
Cl ifi ti f RP P
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Classification of RP ProcessesGenerative Manufacturing Process / Rapid Prototyping / Solid Freeform Fabrication
Solid Paste Liquid Gaseous
WireOne or multi-
Component powderFoil
Melting &Re-solidification
Fused Layer ModelingBallistic Part
Manufacturing
Cutting & GluingLayer LaminatedManufacturing
Cutting &Polymerization
Solid FormPolymerization
PolymerizationPaste
Polymerization Process
Solidification bybinder
3D Printing
Melting &Re-solidification
Selective LaserSintering
Polymerization
Heat
ThermalPolymerization
Lamp
Solid GroundCuring
Light of One Frequency
Laser BeamStereolitho ra h
HolographyHolographic
Interference Solidification
ChemicalReaction
LCVD
St lith h
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Stereolithography
[Courtesy: Kai & Fai]
R id P t t i A li ti
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Rapid Prototyping Applications Design
CAD Model Verification Visualization Object
Proof-of-Concept
Engineering, Analysis and Planning
Form and Fit Models
Flow Analysis
Stress Distribution
Mock-up
Diagnostic and Surgical Operation Planning
Design and Analysis of Custom Prosthesis and
Implants
R id P t t i A li ti
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Rapid Prototyping Applications
Manufacturing
Plastic Mold Parts
Vacuum Casting
Metal Spraying
Casting Sand Casting
Investment Casting
Die Casting
EDM Electrodes
Master Models
R id P t t i P d t
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Rapid Prototyping Products
Engine Manifold Valve
Medical Implant Electronic Packaging
R id P t t i P d t
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Rapid Prototyping Products
Complexity of Object to be manufactured is not a limitation in
Rapid Prototyping
R id P t t i P d t
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Rapid Prototyping Products
SL Model for resection template Silicon Implant molded from a tool
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