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RAPID PROTOTYPING

ABSTRACT

The term rapid prototyping (RP) refers to a class of technologies that can automatically construct
physical models from Computer-Aided Design (CAD) data. It is also called Desktop Manufacturing or
Freeform Fabrication. These technologies enable us to make even complex prototypes that act as an
excellent visual aid to communicate with co-workers and customers. These prototypes are also used for
design testing.

Why Rapid Prototyping?

 Objects can be formed with any geometric complexity or intricacy without the need for elaborate
machine set-up or final assembly.
 Freeform fabrication systems reduce the construction of complex objects to a manageable,
straightforward, and relatively fast process.
 These techniques are currently being advanced further to such an extend that they can be used
for low volume economical production of parts.
 It significantly cut costs as well as development times.

The Basic Processes

RP is basically a five-step process.

1. Create a CAD model of the design

2. Convert the CAD model to STL format

3. Slice the STL file into thin cross-sectional layers

4. Construct the model one layer atop another
5. Clean and finish the model

RAPID PROTOTYPING TECHNIQUES

RP Techniques have proven to be more convenient in building complex prototypes. This is because these
processes are additive in nature unlike conventional subtractive processes. At least six different rapid
prototyping techniques are commercially available, each with unique strengths.


S T L - Stereolithography

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STEREOLITHOGRAPHY

Stereolithography was the first RPT developed in United States in 1986. It uses a photosensitive polymer
that solidifies when exposed to UV light. The model is built upon a platform situated just below the surface
in a vat of liquid epoxy or acrylate resin. The object is built layer by layer. A low power highly focussed UV
laser is used to solidify the first layer leaving the excess areas liquid. This processes is repeated until the
desired shape according to the CAD model is obtained.

LAMINATED OBJECT MANUFACTURING

In LOM layers of adhesive-coated sheet material are bonded together to form a prototype. The model
material consists of paper laminated with heat-activated glue. The paper is pressed on to the base using a
heated roller. A focused laser cuts the outline of the first layer into the paper and then crosshatches the
excess area. The next layer is built on top of the first layer in the same manner. The hatched parts
(excess area) are removed after the final layer is bonded. The final model has a wood like texture and
since it is made of paper the model has to be varnished to prevent moisture damage.

SOLID GROUND CURING


Rapid Prototyping Technology

Laminated Object Manufacturing

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Solid Ground Curing (SGC) is somewhat similar to stereolithography (SLA) in that both use ultraviolet light
to selectively harden photosensitive polymers. First, photosensitive resin is sprayed on the build platform.
Next, the machine develops a photo mask (like a stencil) of the layer to be built. The mask is exposed to
UV light and the exposed parts are solidified. 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.

FUSED DEPOSITION MODELING

In this technique the heated thermoplastic is sent through an extrusion mould. The thin beads thus
obtained are deposited on the build platform to form the first layer. The platform is maintained at lower
temperature for the thermoplastic to harden quickly. After the first layer is formed the platform lowers
and the extrusion head deposits the next layer on top of the first layer.

APPLICATIONS

Prototyping
Rapid Tooling
Rapid Manufacturing
Heterogeneous Modelling

Surface finish, laminated object

manufacturing(LOM).

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ADVANTAGES

 Objects having Complex geometry can be easily manufactured.

 Better surface finish.
 Materials used are cheaper.
 Considerable reduction in production time.
 Less wastage of build-materials.
 RP manufacturers are dramatically reducing build time.

DISADVANTAGES

The polymer material has to be in a special form to be used for prototyping.

Less tensile strength
Not economical for manufacture of simple designs.
Not suitable for small-scale production.
Physical properties of the part change with method of manufacture.
Since the objects are made layer by layer there is a “Stair Stepping Effect”.

CONCLUSION

Rapid prototyping is starting to change the way companies design and build products. Today’s
commercially available machines are accurate to ~0.08 millimetres in the x-y plane, but less in the z
(vertical) direction. Improvements in laser optics and motor control should increase accuracy in all three
directions. In addition, RP companies are developing new polymers that will be less prone to curing and
temperature-induced war page.

The introduction of non-polymeric materials, including metals, ceramics, and composites, represents
another much anticipated development. These materials would allow RP users to produce functional parts.
Today’s plastic prototypes work well for visualization and fit tests, but they are often too weak for function
testing. More rugged materials would yield prototypes that could be subjected to actual service conditions.
In addition, metal and composite materials will greatly expand the range of products that can be made by
rapid manufacturing.

The United States currently dominates the field, but Germany, Japan, and Israel are making inroads. In
time RP will spread to less technologically developed countries as well. With more people and countries in
the field, RP’s growth will accelerate further.

OUTLINE

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Definition – Complexity of models – CAD Model – Development from models using RP Technique – STL –
LOM – Areas of use – Tooling – Building Models – Economical – Recently Developed – Scope

REFERENCES

1. Processes and Materials of Manufacture by R.A. LINDBERG

2. SEMINAR TOPIC FROM :: www.edufive.com/seminartopics.html

3. www.pcmag.com/encyclopedia

4. www.me.sc.edu
5. Serope Kalpakjian & Steven R Schimid “ Manufacturing Process for Engg. Materials”
6. R. K Jain “ Production Technology”
7. www.me.psu.edu

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