Rapid Prototyping

Dr. Lotfi K. Gaafar The American University in Cairo Department of Mechanical Engineering
gaafar@aucegypt.edu (202) 797-5355 Dr. Lotfi K. Gaafar 2002

Introduction
Rapid Prototyping (RP) techniques are methods that allow designers to produce physical prototypes quickly. It consists of various manufacturing processes by which a solid physical model of part is made directly from 3D CAD model data without any special tooling. The first commercial rapid prototyping process was brought on the market in 1987. Nowadays, more than 30 different processes (not all commercialized) with high accuracy and a large choice of materials exist. These processes are classified in different ways: by materials used, by energy used, by lighting of photopolymers, or by typical application range.
Dr. Lotfi K. Gaafar 2002

The Rapid Prototyping Technique

In the Rapid Prototyping process the 3D CAD data is sliced into thin cross sectional planes by a computer. The cross sections are sent from the computer to the rapid prototyping machine which build the part layer by layer. The first layer geometry is defined by the shape of the first cross sectional plane generated by the computer. It is bonded to a starting base and additional layers are bonded on the top of the first shaped according to their respective cross sectional planes. This process is repeated until the prototype is complete.
Dr. Lotfi K. Gaafar 2002

Rapid Prototyping Technique Process Flow

3D Solid modeling

Data preparation

Part Building

Pass

Reject Redesign

Dr. Lotfi K. Gaafar 2002

Prototyping- What is it ?

. Physical Model of the product . Degrees of Prototyping . Full Complete scale Model - functional model . Scaled Model - functional/ simulated material . Geometrical configuration . Partial .

Dr. Lotfi K. Gaafar 2002

Prototyping- Why?
 Visualization  Design Change (iterations)  Free Form Prototyping (complex object fabrication/ visualization)  Testing Fit/ Packaging  Cost, Time, and resource estimation  Process Planning  First to Market -- Critical for todays industry  Rapid production (concurrent activities)  JIT concept (0 Inventory)  Rapid tooling / no tooling -- trend in technology

Dr. Lotfi K. Gaafar 2002

Prototyping- Why?

Design verification
     

Design for manufacturability Design for assembly Design for maintainability Design for reliability Design for Quality Design Parameters (Tolerances/ allowances)

 Concurrent Engineering  Tooling . Reverse Engineering . Die fabrication . Tool Path generation  Limited Production

Dr. Lotfi K. Gaafar 2002

Classification of Prototyping Technology

 Subtractive Processes (Material Removal)

.., when used for prototype production  Degree of automation vary
 Ex : Stereolithography  Degree of sophistication vary

 Ex : Milling, turning, grinding,-- machining centers

 Additive (Material Build-up)  Formative (Sculpture)

 Ex : Forging, Casting, ..  When used for Prototyping, it is usually manual

Dr. Lotfi K. Gaafar 2002

Sophistication of Prototyping Technology

Such Technology is known by different terms, such as :
    

Desktop Manufacturing Rapid Prototyping Tool-less Manufacturing 3-D printing Free form Fabrication (F3)

Dr. Lotfi K. Gaafar 2002

Sophistication of Prototyping Technology  Fabrication process :  Degree of Automation :

The process must take a material in some shapeless form, and turn out solid objects with definite shape

 Ability to build complex objects

High degree of automation. Since Prototyping is a stage in a cycle, it is expected that the technology will enable automated chaining to the before and after links in the cycle. The more complex the build object, the more sophistication in the technology.

Dr. Lotfi K. Gaafar 2002

Sophistication of Prototyping Technology

 Tooling (no Tooling): Less tools is better  One shot operations: No assembly of parts, ..etc.  Time: The less time the better it is  The closeness to serve the purpose of the prototype: Accurate representation of the design  Flexible: Modifications, addition of parameters, scaling  Equipment: size, weight, maintenance..etc  Economical: Both equipment and operating costs  Clean, safe operation  User friendly

Dr. Lotfi K. Gaafar 2002

Rapid Prototyping Processes

 SLS --- Selective Laser Sintering  SLA --- Stereolithography  LOM --- Laminated Object Manufacturing  FDM --- Fused Deposition Modeling  Others

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- SLS

Selective Laser Sintering

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- SLS

Application Range
 Visual Representation models  Functional and tough prototypes  cast metal parts

Advantages

 Flexibility of materials used PVC, Nylon, Sand for building sand casting cores, metal and investment casting wax.  No need to create a structure to support the part  Parts do not require any post curing except when ceramic is used.

Disadvantages

 During solidification, additional powder may be hardened at the

border line.  The roughness is most visible when parts contain sloping (stepped) surfaces.

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- SL

Stereolithography

Dr. Lotfi K. Gaafar 2002

Rapid Prototyping Resin

 Basic Polymer Chemistry  SL Resin : It is a liquid photocurable resin Characteristics Fully 100% reactive component Energy efficient requiring 50 to 100 times less energy than thermally cured coatings  Polymerization : It is the process of linking small molecules (monomers) into larger molecules (polymers) comprised of many monomer units.  As polymerization occurs (chemical reaction) many properties changes, shear strength increase, density increased as resin changes from liquid to solid (shrinkage)  Polymerization occurs in SL through the exposure of liquid resin to laser. The layer thickness to be polymerized is given by the amount of liquid which has been recoated onto the part, and any excess laser radiation that penetrates this layer acts to slightly increase the curing of the previous layers.  The important properties for selecting the resin has to do with posture shrinkage and the resulting posture distortions.

Dr. Lotfi K. Gaafar 2002

Desirable features of SL resin

        Improved Impact resistance (less brittleness) Greater Flexibility Improved photospeed Increased Strength Better overall part accuracy Electrical conductivity High temperature resistance Solvent resistance or vice versa

Dr. Lotfi K. Gaafar 2002

Some measures to reduce distortions

 Use high exposure and slow scan speed such that polymerization is essentially complete under the laser spot.  Use resin with a faster rate of polymerization  Decrease laser power to decrease scan speed for a given exposure.  Use low-shrinkage resin  Increase layer thickness to increase the strength

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- SL

Application Range
 Parts used for functional tests  Manufacturing of medical models  Form fit functions for assembly tests

Advantages

 Possibility of manufacturing parts which are impossible to be

produced conventionally in a single process  Can be fully atomized and no supervision is required.  High Resolution  No geometric limitations

Disadvantages

 Necessity to have a support structure  Require labor for post processing and cleaning

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- LOM

Laminated Object Manufacturing

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- LOM

Application Range
 Visual Representation models  Large Bulky models as sand casting patterns

Advantages

 Variety of organic and inorganic materials can be used Paper, plastic, ceramic, composite  Process is faster than other processes  No internal stress and undesirable deformations  LOM can deal with discontinuities, where objects are not closed

completely

Disadvantages

layers.  Parts with thin walls in the z direction can not be made using LOM  Hollow parts can not be built using LOM

 The stability of the object is bonded by the strength of the glued

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- FDM

Fused Deposition Modeling

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- FDM

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes- FDM

Application Range
 Conceptual modeling  Fit, form applications and models for further manufacturing

procedures  Investment casting and injection molding

Advantages

 Quick and cheap generation of models  There is no worry of exposure to toxic chemicals, lasers or a

liquid chemical bath.

Disadvantages

 Restricted accuracy due to the shape of material used, wire is 1.27

mm diameter.

Dr. Lotfi K. Gaafar 2002

Rapid prototyping Processes Other Processes

Ballistic Particle Manufacturing (BPM) This process uses a 3D solid model data to direct streams of material at a target. 3D Printing It creates parts by layered printing process. The layers are produced by adding a layer of powder to the top of a piston and cylinder containing a powder bed and the part is being fabricated. Model Maker It uses ink jet printer technology with 2 heads. One deposits building material, and the other deposits supporting wax.
Dr. Lotfi K. Gaafar 2002

Rapid Prototyping Products

Dr. Lotfi K. Gaafar 2002