ASSIGNMENT NO.

3
RAPID PROTOTYPING AND TOOLING

RAPID PROTOTYPING
Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate a scale
model of a part or assembly using three-dimensional computer aided design (CAD) data.
Rapid Prototyping has also been referred to as solid free-form manufacturing; computer
automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for
visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put
into a wind tunnel. RP models can be used to create male models for tooling, such as silicone
rubber molds and investment casts. In some cases, the RP part can be the final part, but typically
the RP material is not strong or accurate enough. When the RP material is suitable, highly
convoluted shapes (including parts nested within parts) can be produced because of the nature of
RP.
There is a multitude of experimental RP methodologies either in development or used by small
groups of individuals. This section will focus on RP techniques that are currently commercially
available, including Stereolithography (SLA), Selective Laser Sintering (SLS), Laminated Object
Manufacturing (LOM), Fused

Deposition

Modeling (FDM), Solid

Ground

Curing (SGC),

and Ink Jet printing techniques.

Why Rapid Prototyping?

To increase effective communication.

To decrease development time.

To decrease costly mistakes.

To minimize sustaining engineering changes.

To extend product lifetime by adding necessary features and eliminating redundant

features early in the design.

RP decreases development time by allowing corrections to a product to be made early in the

process. By giving engineering, manufacturing, marketing, and purchasing a look at the product
early in the design process, mistakes can be corrected and changes can be made while they are
still inexpensive. The trends in manufacturing industries continue to emphasize the following:

 Increasing number of variants of products.

Increasing product complexity.
Decreasing product lifetime before obsolescence.
Decreasing delivery time.

Rapid Prototyping improves product development by enabling better communication in a

concurrent engineering environment

Methodology of Rapid Prototyping

The basic methodology for all current rapid prototyping techniques can be summarized as
follows:
1. A CAD model is constructed, then converted to STL format. The resolution can be set to
minimize stair stepping.
2.

The RP machine processes the .STL file by creating sliced layers of the model.

3.

The first layer of the physical model is created. The model is then lowered by the thickness
of the next layer, and the process is repeated until completion of the model.

4.

The model and any supports are removed. The surface of the model is then finished and
cleaned.

Types of Rapid Prototyping:

Stereolithography is one of the most common types of Rapid Prototyping processes. A
computer controlled UV laser draws the image of the object on the surface of liquid plastic. The
laser takes passes at hitting the liquid plastic and thereby hardening it. At the completion of each
pass, the object would be lowered so that the UV laser could go through its next pass this
process continues and the end result is a carved out 3-D physical model of the object.

Selective laser sintering also works with a high powered laser as the laser selectively
moves over the surface of thermoplastic powder it fuses cross-sections of the material layer by
layer. As one layer is completed, the process is repeated by lowering the powdered bed and
adding a fresh layer of material.

3-D Printing is the process in which a liquid adhesive is applied to layers of powder via an
ink-jet head.

Fused Deposition Modeling is a additive manufacturing process that was developed in the
1980s by S. Scott Crump. The Fused Deposition Modeling (FDM) process consists of having a
heated melted thread of plastic pass onto a laid down build-platform in a layer by layer fashion
via an extrusion nozzle. The nozzle is controlled by a mechanical device and a computer aided
manufacturing software which holds the final image of the product. Upon hitting the build
platform, the liquid solidifies and the platform lowers where the next layer of liquid is laid upon
it. This process continues until the product is complete.

Rapid Prototyping allows one to produce very accurate, beautiful and complex objects to suit
an array of purposes. It is as a high end tool thats being used for diagnostics, pre-operative
planning, concept modeling and early design flaw detection. Its a technology that is making its
way into almost every aspect of our lives - from education and art to manufacturing, engineering,
medicine and architecture.

ADVANTAGES
Time Savings
By eliminating the time needed to produce molds, patterns and special tools required for
conventional modeling, rapid prototyping reduces time between initial design and analysis. An
accurate model is quickly available for testing form, features, performance and usability. Rapid
prototyping is a highly automated process that enables designers to quickly modify products in
line with feedback. The time savings can help organizations gain competitive advantage by
bringing new products to market quickly, ahead of competitors.

Cost Reduction
Rapid prototyping helps to reduce the costs of product development. There is no need to develop
special tools for each new product. Rapid prototyping uses the same CAD and printing
equipment each time. The automated prototyping process also reduces staff costs. The costs of
waste are lower, because the prototyping technique only adds modeling material where needed.
Conventional prototyping techniques create waste through cut-off material or chippings as the
tools create the finished model.

Easier Visualization
The ability to create a realistic three-dimensional scale model helps designers present new
product concepts to stakeholders, such as board members, clients or investors who need to
understand and approve the development program. Designers can also gain feedback from
potential users and customers that is based on physical products, rather than concepts, enabling
them to incorporate realistic usability data into the later stages of development.
Lower Risk
By enabling detailed physical analysis at an early stage in the development program, rapid
prototyping can reduce the risk of costly errors. The development team can identify design faults
or usability problems and make any modifications quickly. The iterative process provides a
precise model for production tooling, reducing the risk of later manufacturing problems.
Support for Customization
Rapid prototyping is an iterative process, so it is easy to incorporate individual customers
requirements and create customized products cost effectively. Development teams do not have to
design each customized product from scratch. Customization can provide a strong competitive
advantage by offering customers greater choice and flexibility.
Realizing the Design Concepts
Rapid prototyping allows designers to realize their concepts beyond virtual visualization. This
enables to understand the look and feel of the design, rather than simply assuming through the

CAD model. This helps designers to carry forward their ideas and implement them in their
design prior to finalization. It also provides a proof of concept for the end client, seeking for a
more realistic product design rather than merely visualizing the design on screen.
Incorporating the Changes Instantly
Having a physical model in hand, it is possible to incorporate the changes instantly merely by
asking the feedback from the customers. Prior to finalizing the design, there are several iterations
required. With each iterative process, the design improves further, building confidence for both
the designer as well as the end consumer. This also helps in identifying the actual need of the
market, making possible to develop competitive products with better acceptance rate.
Minimizing Design Flaws
The additive manufacturing offers the ability to identify flaws in the design prior to mass
production. The materials available for rapid prototyping closely resemble the properties and
strength of the actual product, making it possible to perform physical tests easily. The risks of
faults and usability issues can be identified earlier to avoid problems that might occur later
during manufacturing process.

DISADVANTAGES :
Insufficient analysis: The focus on a limited prototype can distract developers from properly
analyzing the complete project. This can lead to overlooking better solutions, preparation of
incomplete specifications or the conversion of limited prototypes into poorly engineered final
projects that are hard to maintain. Further, since a prototype is limited in functionality it may not
scale well if the prototype is used as the basis of a final deliverable, which may not be noticed if
developers are too focused on building a prototype as a model.

User confusion of prototype and finished system: Users can begin to think that a prototype,
intended to be thrown away, is actually a final system that merely needs to be finished or
polished. (They are, for example, often unaware of the effort needed to add error-checking and
security features which a prototype may not have.) This can lead them to expect the prototype to
accurately model the performance of the final system when this is not the intent of the

developers. Users can also become attached to features that were included in a prototype for
consideration and then removed from the specification for a final system. If users are able to
require all proposed features be included in the final system this can lead to conflict.

Developer misunderstanding of user objectives: Developers may assume that users share their
objectives (e.g. to deliver core functionality on time and within budget), without understanding
wider

commercial

issues.

For

example,

user

representatives

attending Enterprise

software (e.g. PeopleSoft) events may have seen demonstrations of "transaction auditing" (where
changes are logged and displayed in a difference grid view) without being told that this feature
demands additional coding and often requires more hardware to handle extra database accesses.
Users might believe they can demand auditing on every field, whereas developers might think
this is feature creep because they have made assumptions about the extent of user requirements.
If the solution provider has committed delivery before the user requirements were reviewed,
developers are between a rock and a hard place, particularly if user management derives some
advantage from their failure to implement requirements.

Developer attachment to prototype: Developers can also become attached to prototypes they
have spent a great deal of effort producing; this can lead to problems like attempting to convert a
limited prototype into a final system when it does not have an appropriate underlying
architecture. (This may suggest that throwaway prototyping, rather than evolutionary
prototyping, should be used.)

Excessive development time of the prototype: A key property to prototyping is the fact that it
is supposed to be done quickly. If the developers lose sight of this fact, they very well may try to
develop a prototype that is too complex. When the prototype is thrown away the precisely
developed requirements that it provides may not yield a sufficient increase in productivity to
make up for the time spent developing the prototype. Users can become stuck in debates over
details of the prototype, holding up the development team and delaying the final product.

Expense of implementing prototyping: the start up costs for building a development team
focused on prototyping may be high. Many companies have development methodologies in

place, and changing them can mean retraining, retooling, or both. Many companies tend to just
jump into the prototyping without bothering to retrain their workers as much as they should.

- EXAMPLES OF RAPID TOOLING

Rapid manufacturing
Rapid Manufacturing is an additive fabrication technique for manufacturing
solid objects by the sequential delivery of energy and/or material to specified points in
space to produce that part. Current practice is to control the manufacturing process by
computer using a mathematical model created with the aid of a computer. Rapid
Manufacturing done in parallel batch production can provide a large advantage in speed
and cost compared to alternative manufacturing techniques such as plastic injection
molding or die casting. Rapid Manufacturing may involve custom parts, replacement
parts, short run production, or series production. (When the part is used in the
development process only, the appropriate term is Rapid Prototyping.)

Aerospace and marine

Wind tunnel models
Functional prototypes
Boeings on demand-manufacturing

Automotive and rp services

Needed from concepts to production level
Reduced time to market
Dies and molds
Functional testing

Biomedical science
Customized surgical implants
Mechanical bone replica
Forensics
Prosthetic parts
3d visualization for education and training
Pre surgical planning model

Architecture
3d visualization
Iteration of shapes
Sectioned models

Fashion and jewelry

Shoe design
Jewelry
Pattern for lost wax

Sculptures
3d scanning
Replica
Original works
Layered fabrication

Additive manufacturing
Additive Manufacturing is the process of making a product by adding layers
in a relatively efficient way, such that there is little w.aste or reduction of materials. Two
examples are inkjet printing and aerosol jet printing of electronic circuits. In comparison
to photolithography where the manufacturer must remove much of the material that is
deposited to create a given layer of the product, inkjet and aerosol jet printing only use
material where it is needed with little or no waste