Rapid Prototyping

A prototype is the first or original example of something that has or will be copied or developed. It is the model of preliminary version.

or

An approximation of a product or its components in some form for a definite purpose in its implementation.

Types of Prototypes• The implementation of the prototype: From the entire product itself or its subassemblies and components.

• The form of prototype: from a virtual prototype to a physical prototype.

• The degree of approximation of the prototype from very rough representation to exact replication of the product.

• Experimentation and learning

• Testing and proofing

• Communication and interaction

• Synthesis and integration and

• Scheduling and markets.

Roles of Prototypes

1770 Mechanization1946 First computer1952 First CNC machine tool1960 First commercial laser1961 First commercial robot1963 Fist interactive graphics system1988 First commercial Rapid prototyping system

Historical Developments

Three phases of development

First phase: Manual prototyping

Second phase: Soft or virtual prototyping

Third phase: Rapid prototyping

Fundamentals of Rapid Prototyping

• Input

• Material

• Method

• Application

RP wheel

Advantages of Rapid Prototyping

Direct Benefits

Benefit to Product Designer

Benefit to the Tooling and Manufacturing EngineerIndirect Benefits

Benefit to Marketing

Benefit to the Consumer

Disadvantages of Rapid Prototyping

• The price of machinery and materials are expensive.

• The surface is usually rougher than machined surfaces.

• Some materials are brittle.• The strength of RP-parts are weaker in z-

direction than in other.

Classification of Rapid Prototyping Systems

• Solid based

• Liquid based and

• Powder based system

The classification is done based on the type of material used for Prototyping.

Solid based RP systems

1. Fused Deposition Modeling (FDM) (Stratasys)2. Bench top system (Solids cape)3. Laminated Object Manufacturing (LOM) (Cubic

Technologies)4. Multi-jet Modeling system (MJM) (3D Systems)5. Paper Lamination Tech (PLT)(Kira) 6. CL 100 (CAM-LEM)7. Offset Fabbers (Ennex Corporation)8. Shape Deposition Manufacturing process

1. Stereo lithography Apparatus (3D systems)2. Polyjet (Objet Geometries Ltd.)3. Solid creation system (D-MEC)4. Perfactory (EnvisionTec)5. Solid Object Ultraviolet laser Printer (SOUP) (CMET)6. Bioplotter (EnvisionTec)7. Rapid freeze prototyping 8. ACCULAS (D-MEC)9. Two Laser Beams 10. Solid ground curing (SGC) (Cubital)11. Soliform system (Teijin Seiki)12. Rapid prototyping system (Meiko)

Liquid based RP systems

Powder based RP systems

1. Selective Laser Sintering (SLS) (3D system)2. Three Dimensional Printing (3DP) (Z Corporation)3. Laser Engineered Net Shaping (LENS) (Optomec)4. Electron Beam Melting (EBM) (Arcam)5. Selective Mask Sintering(SMS) (Sintermask Technologies )6. Micro Sintering (3D-Micromac)7. ProMetal (The Ex One Company)8. Direct Shell Production Casting (DSPC) (Soligen)9. Multiphase Jet Solidification (MJS) (Fraunhofer)10. Lasform Technology (Aeromet Corporation)

Fundamental Automated Process

Rapid Prototyping Process Chain

• 3D modeling• Data conversion and Transmission• Checking and preparing• Building• Post processing

Tessellation of 3D model

Slicing of 3D model