Lecture 4 Rapid Prototyping PDF

LECTURE 04 : RAPID PROTOTYPING
Adib Bin Rashid

Assistant Professor
IPE Department, MIST
What is a Prototype?
A prototype is a draft version or an approximation of a final product.
Prototypes are developed for several reasons:
 to identify possible problems that were not identified in previous
stages of the design process.
 to confirm the suitability of a design prior to starting mass
production.
 Provides a scale model to conduct tests and verify performance.
 for visualization purposes.
 Some prototypes are used as market research and promotional tools.
Most importantly, it is cheaper to manufacture, test and make changes to
a prototype than it is to a final product.
DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 2

Rapid Prototyping
• Rapid prototyping technologies are able to produce physical model in a layer by layer
manner directly from their CAD models without any tools, dies and fixtures and also with
little human intervention.
• RP is capable to fabricate parts quickly with too complex shape easily as compared to
traditional manufacturing technology.
• RP helps in earlier detection and reduction of design errors.
Steps in Rapid Prototyping :
 Create a CAD model of the design

 Convert the CAD model to STL format (stereo lithography)
 Slice the STL file into thin cross-sectional layers
 Construct the model one layer atop another
 Clean and finish the model

Rapid Prototyping
Basics of model generation by rapid prototyping

• CAD Model Creation

• First, the object to be built is modeled using a Computer-Aided Design (CAD) software
package or coordinate measuring machine or laser scanner.
• Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately
than wire-frame modelers such as AutoCAD, and will therefore yield better results.
• This process is identical for all of the RP build techniques.

 Conversion to STL Format:

• To establish consistency, the STL (stereo lithography, the first RP technique) format has been
adopted as the standard of the rapid prototyping industry and acts as the interface b/w CAD
software and machines.
• The second step, therefore, is to convert the CAD file into STL format. This format
represents a three-dimensional surface as an assembly of planar triangular facets.
• STL files use planar elements, they cannot represent curved surfaces exactly. Increasing the
number of triangles improves the approximation.

 Slice the STL File:

• In the third step, a pre-processing program prepares the STL file to be built.
• The pre-processing software slices the STL model into a number of layers from 0.01 mm
to 0.7 mm thick, depending on the build technique.
• The program may also generate an auxiliary structure to support the model during the
build. Supports are useful for delicate features such as overhangs, internal cavities, and thin-
walled sections.

 Layer by Layer Construction:
• The fourth step is the actual construction of the part.
• RP machines build one layer at a time from polymers, paper, or powdered metal.
• Most machines are fairly autonomous, needing little human intervention.
 Clean and Finish:

• The final step is post-processing. This involves removing the prototype from the machine and
detaching any supports.
• Some photosensitive materials need to be fully cured before use
• Prototypes may also require minor cleaning and surface treatment.
• Sanding, sealing, and/or painting the model will improve its appearance and durability.

Fundamentals of Rapid Prototyping
The Rapid Prototyping Wheel depicting the 4 major aspects of RP
• INPUT
• METHOD
• MATERIAL
• APPLICATION

 INPUT
 Input refers to the electronic information required to describe the physical object with
3D data.
 There are two possible starting points – a computer model or a physical model.
 The computer model created by a CAD system can be either a surface model
or a solid model
 On the other hand, 3D data from the physical model is not at all straightforward.
 It requires data acquisition through a method known as reverse engineering.
 In reverse engineering, a wide range of equipment digitizer, to capture data points of the
physical model and “reconstruct” it in CAD system.

METHOD
 While they are currently more than 20 vendors for RP systems, the method employed by
each vendor can be generally classified into the following categories:
• photo-curing,
• cutting and gluing/joining,
• melting and solidifying/fusing and joining/binding.
 Photo-curing can be further divided into categories of
• single laser beam,

• double laser beams and
• masked lamp

 MATERIAL
 The initial state of material can come in either
• solid, liquid or powder state.
 In solid state, it can come in various forms such
• a pallets, wire or laminates.
 The current range materials include
• paper, nylon, wax, resins, metals and ceramics.
 APPLICATIONS
 Applications can be grouped into:
• Design
• Engineering, Analysis and Planning
• Tooling and Manufacturing
 A wide range of industries can benefit from RP and these include, but are not limited to,
• aerospace,
• automotive,
• biomedical, consumer,
• electrical and electronics products.

Advantages/Disadvantages
• Almost any shape or geometric feature can be
produced.
• Reduction in time and cost (could range 50 –90%.
Wohler) • The price of machinery and
materials.
• Errors and flaws can be detected at an early stage.
• RP/RM can be used in different industries and fields • The surface is usually rougher
of life than machined surfaces.
(medicine, art and architecture, marketing..) • Some materials are brittle.
• Discussions with the customer can start at an early
stage.
• The strength of RP-parts are
weaker in z-direction than in
• Assemblies can be made directly in one go. other.
• Material waste is reduced.
• No tooling is necessary.
• The designers and the machinery can be in separate
places.
DEPARTMENT
• OF INDUSTRIAL & PRODUCTION ENGINEERING 13
Rapid Prototyping
Rapid prototyping is a broad term that comprises many different technologies used to
quickly fabricate a physical model directly from computer data.
The first rapid prototyping method, called stereo lithography, was developed in the late
1980s, but more sophisticated techniques are available today.
The term “rapid” is relative. Some prototypes may take hours or even days to build
(still much faster than the weeks that may be required for a technician to machine a
design out of metal).
Rapid prototyping systems are additive manufacturing processes that work on the basic
principle of producing a 3D part by building and stacking multiple 2D layers together.
Most common types of rapid prototyping systems:
 SLA (Stereo Lithography)
 SLS (Selective Laser Sintering)
 LOM (Laminated Object Manufacturing)
 FDM (Fused Deposition Modeling).
Different technologies use different materials to produce the parts.
Types of Rapid Prototyping
─────────────────────────────────────────────────────────────────────────────────────
 LIQUID-BASED
• Liquid-based RP systems have the initial form of its material in liquid state.
• Through a process commonly known as curing, the liquid is converted into the solid
state.
 SOLID-BASED
• Except for powder, solid-based RP systems are meant to encompass all forms of material in
the solid state.
• In this context, the solid form can include the shape in the form of a wire, a roll, laminates
and pallets.
 POWDER-BASED
• In a strict sense, powder is by-and-large in the solid state.
• However, it is intentionally created as a category outside the solid- based RP systems to
mean powder in grain-like form.

Types of Rapid Prototyping

STEREO LITHOGRAPHY (SLA)
 Uses a liquid photosensitive resin as building material and a low power laser
to build the part one layer at a time.
 The 3D part is produced on a flat platform that is gradually submerged on a
pool filled with photosensitive liquid resin.
 For each layer, a laser beam traces out the corresponding cross-section
pattern of the part on the surface of the liquid container.
 The pattern is then solidified and added to the layer below.
 The platform descends one layer thickness (the layer thickness depends on
the precision of the machine) and the process repeats.
 When the process finishes, the part is immersed in a chemical bath for
cleaning and removing excess material
https://www.youtube.com/watch?v=jeCHKDxQQh0
Abbreviation: SLA
Material type: Liquid(Photopolymer)

Materials: Thermoplastics(Elastomers)
Min layer thickness: 0.02 mm
Surface finish: Smooth
Build speed: Average
Applications: Form/fit testing, Functional
testing, Very detailed parts,
Presentation models, Snap fits..

ADVANTAGES DISADVANTAGES
 Achieving accuracy in  Requires post-curing.

industries
 Some war page, shrinkage and curl
 Capable of high detail and thin due to phase change.
walls
 Limited materials (Photo
 Good surface finish polymers).
 High part complexity  Support structures always needed.

Removal of support structures can
be difficult.


Working
 A vat containing a mechanism whereby a platform can be lowered and
raised is filled with a photocurable liquid-acrylate polymer.
 The liquid is a mixture of acrylic monomers, oligomers (polymer
intermediates), and a photoinitiator ( a compound that undergoes a
reaction upon absorbing light).
 At its highest position (depth a), a shallow layer of liquid exists above the
platform.
 A laser generating an ultraviolet (UV) beam is focused upon a selected
surface area of the photopolymer and then moved around in the x-y
plane.
 The beam cures that portion of the photopolymer and thereby
produces a solid body.

Working
 The platform is then lowered sufficiently to cover the cured polymer with
another layer of liquid polymer, and the sequence is repeated.
 The process is repeated until level b is reached. Thus far, we have generated a
cylindrical part with a constant wall thickness. Note that the platform is now
lowered by a vertical distance ab.
 At level b, the x-y movements of the beam define a wider geometry, so we now
have a flange-shaped portion that is being produced over the previously
formed part.
 After the proper thickness of the liquid has been cured, the process is
repeated, producing another cylindrical section between levels b and c.
 Note that the surrounding liquid polymer is still fluid (because it has not been
exposed to the ultraviolet beam) and that the part has been produced from the
bottom up in individual „slices‟. The unused portion of the liquid polymer can
be used again to make another part or another prototype.
Working

Process chain of SLA

Process chain of SLA (Cont..)
https://www.youtube.com/watch?v=yW4EbCWaJHE
https://www.youtube.com/watch?v=-_Xnpn_d4aM

SELECTIVE LASER SINTERING (SLS)
 Uses a high power laser and powdered materials. A wide variety of materials can be used, ranging
from thermoplastic polymers, such as nylon and polystyrene, to some metals.
 3D parts are produced by fusing a thin slice of the powdered material onto the layers below it. The
surfaces of SLS prototypes are not as smooth as those produced by SLA processes. However,
SLS parts are sufficiently strong and resistant for many functional tests.
 The powdered material is kept on a delivery platform and supplied to the building area by a roller.
For each layer, a laser traces the corresponding shape of the part on the surface of the building
area, by heating the powder until it melts, fusing it with the layer below it.
 The platform containing the part lowers one layer thickness and the platform supplying the
material elevates, providing more material to the system.
 The roller moves the new material to the building platform, leveling the surface, and the process
repeats.
 Some SLS prototype machines use two delivery platforms, one on each side of the building
platform, for efficiency, so the roller can supply material to the building platform in both
directions.
https://www.youtube.com/watch?v=ruvRijM7f50
• A laser beam is used to fuse the powder within the section boundary through a cross-
hatching motion.
• The table is lowered through a distance corresponding to the layer thickness (usually
0.01 mm) before the roller spreads the next layer of powder on the previously built
layer.
• The unsintered powder serves as the support for overhanging portions, if any in the
subsequent layers.

Laser system with optical system.
A cylinder, where part is built.
One or more feed pistons which contain fresh powder.
A roller or sweeper for spreading the powder on the powder bed.
All of these
components are
controlled by
computer through
separate
programmable logic
controllers, sensors
and electronics.

Working Procedure

Working Procedure

Working Procedure
 First, a thin layer of powder is
deposited in the part-build
cylinder
 Then, a laser beam guided by a
process-control computer using
instructions generated by the 3D
CAD program of the desired
part is focused on that layer,
tracing and sintering a particular
cross-section into a solid mass.
 The powder in other areas
remains loose, yet it supports the
sintering portion.

Working Procedure
 Another layer of powder is then deposited; this cycle is repeated again and again until
the entire 3D part has been produced.
 The loose particles are shaken off, and the part is recovered.
 The part does not require further curing-unless it is a ceramic, which has to be fired
to develop strength.
 A variety of materials can be used in this process, including polymers (such as ABS;
PVC, nylon, polyester, polystyrene, and epoxy), wax, metals, and ceramics with
appropriate binders.
 It is most common to use polymers because of the smaller and less expensive, and
less complicated lasers are required for sintering.
 With ceramics and metals, it is common to sinter only a polymer binder that has been
blended with the ceramic or metal powders.
 The resultant part can be carefully sintered is a furnace and infiltrated with another
metal if desired.
https://www.youtube.com/watch?v=yiUUZxp7bLQ
Abbreviation: SLS
Material type: Powder(Polymer)
Materials: Thermoplastics: Nylon,

Polyamide and Polystyrene;
Elastomers; Composites
Min layer thickness: 0.10mm
Surface finish: Average
Build speed: Fast
Applications: Form/fit testing, Functional
testing, Less detailed parts,
Parts with snap-fits& living
hinges, High heat applications..
 No need of support structures  Rough surface finish.

 No post curing required  Additional powder may get
 Variety and Flexibility of hardened while solidification along
materials border line
 The main advantage is that the  Mechanical properties below those
fabricated prototypes are porous achieved in injection mouldings
(typically 60% of the density of process for same material.
moulded parts), thus impairing their  Many build variables, complex
strength and surface finish. operation.
 Fast build times.  Material changeover difficult
compared to FDM & SLA.

PROCESS PARAMETERS
All these factors are depending on the
amount of energy delivered into the
surface of the powder.
The shrinkage in laser sintering process is

determined by material
properties and the geometry of the final
part.
The fabricated part accuracy depends on

the shrinkage of the part. The caused
inaccuracies can be overcome by
calibrating and compensating them.

PROCESS PARAMETERS
1. Part bed temperature

2. Layer thickness
3. Laser power The longer the laser dwells in a particular location, the
deeper the fusion depth and the larger the melt pool diameter. Typical layer
thicknesses range from 0.1 to 0.15 mm
4. Laser scan speed
5. Energy density
6. Powder shape

PROCESS PARAMETERS
Process parameters can be lumped into four categories:

• (1) laser-related parameters (laser power, spot size, pulse duration, pulse
frequency, etc.),
• (2) scan-related parameters (scan speed, scan spacing, and scan pattern),
• (3) powder-related parameters (particle shape, size and distribution, powder

bed density, layer thickness, material properties, etc.), and
• (4) temperature-related parameters (powder bed temperature, powder

feeder temperature, temperature uniformity, etc.)
PROCESS PARAMETERS
Energy Density:
• Energy density is defined as the amount of energy input per unit area
• It is dependent upon laser power, scan speed and scan spacing and is determined
by the following equation
• ED = LP / (BS x SS)
• where ED is the energy density, LP is the laser power, BS is the beam scan speed
and SS is the scan spacing.
• The laser power, scan speed and scan spacing need to be optimized according to
the amount of input energy required to fuse the particles in the layer

PROCESS PARAMETERS
Laser, ED = P/(D*V) J/mm² ….(1)

where,
ED = Energy density,
P = laser power,
D = diameter of the laser beam,
V = laser scanning speed.
Laser power, scanning speed and diameter of laser beam are
adjustable values in the laser sintering process.
Eq 1 shows that energy density increases with increase in laser power and
decrease in laser scanning speed and diameter.

PROCESS PARAMETERS
Laser power
 Laser power is determined as power level that is brought by laser beam to the powder bed.
 This factor should be set to ensure that the powder will be heated close to melting temperature during
scanning.
 Overall energy, which is delivered to the powder bed, has an effect to laser power value
used.
Spot size
 Spot size means diameter of laser beam.
 Usually diameter of the sintered area is larger than diameter of the laser beam.
 Spot size has an effect to the final accuracy of the part. Final accuracy is limited by spot size.
Scanning speed
 Scanning speed means the speed of beam that is brought to powder bed.
 Eq1 shows that laser energy density is depending of scanning speed.
 Increase of scanning speed is decreasing energy density.

Hatch spacing
Hatch spacing is the distance
between two neighboring scan
vectors, hatch lines.
 Hatch spacing is usually less

than the laser beam diameter.
 Some areas in the powder bed

are exposed to multiple
scanning. Cross-section may not
be sintered, if the hatch spacing
is too far.

Scan pattern
 Figure shows an typical

example of scan pattern in laser
sintering process.
 Scan pattern is affecting to the surface

quality.
 Scan pattern in X- direction, Y- direction and

X & Y direction

Layer thickness:
• Layer thickness is a measure of the thickness of each layer during the SLS process
• It is also the depth by which the part piston is lowered after the laser scanning of each layer
• A thicker layer requires greater incident energy
• Thicker layers will not give very good surface finish because of „stair stepping‟

Absorption and reflection
Absorption and reflection are in an
extremely important role in laser
material processing, such as laser
sintering.
Laser sintering is based on absorption of
laser energy.
When laser beam incidences powder, it is
partly reflected from surface and partly
absorbed.
There are few properties, which have an
effect on absorption and reflection:
Wave length
Temperature
Surface film
Material and surface roughness

Part bed temperature:
• The part bed is the central region of the SLS machine (DTM Sinterstation 2000)
where the part is built
• The part bed temperature is controlled primarily by the heater underneath the build
area
• The temperature should be lower than melting temperature of the powder
• The higher the temperature is set, the less the incident energy is required during the
SLS process

PROCESS PARAMETERS
Surface finish:-
The surface of an SLS part is powdery, like the base material whose
particles are fused together without complete melting.
If the temperature of uncured SLS powder gets too high, excess fused
material can collect on the part surface.
The smoother surface of an SLA part typically wins over SLS when an appearance
model is desired.
SLA is a better process where fine, accurate detail is required.

PROCESS PARAMETERS
Dimensional accuracy:-
The temperature dependence of the SLS process can sometimes result in
excess material fusing to the surface of the model.
SLA parts suffer from the "trapped volume“ problem in which cups in the
structure that hold fluid cause inaccuracies.
SLA is more accurate immediately after completion of the model.
Support Structures:-
SLA parts typically need support structures during the build.
Marks left after removal of support structures for parts cause dimensional
inaccuracies.
SLS parts, because of the supporting powder, sometimes do not need any support,
but this depends upon part configuration.

LAMINATED OBJECT MANUFACTURING (LOM)
 Laminated Object Manufacturing is a relatively low cost rapid prototyping technology

where thin slices of material (usually paper or wood) are successively glued together to
form a 3D shape.
 The process uses two rollers to control the supply of paper with heat-activated glue to a
building platform.
 When new paper is in position, it is flattened and added to the previously created layers
using a heated roller.
 The shape of the new layer is traced and cut by a blade or a laser. When the layer is
complete, the building platform descends and new paper is supplied.
 When the paper is in position, the platform moves back up so the new layer can be glued
to the existing stack, and the process repeats.
https://www.youtube.com/watch?v=GjJKuteh4xM


Working Procedure
https://www.youtube.com/watch?v=m0b3WIS2nqw&t=39s

Abbreviation: LOM
Material type: Solid(Sheets)

Materials: Thermoplasticssuchas PVC;
Paper;
Composites(Ferrousmetals;
Non-ferrousmetals; Ceramics)
Surface finish: Rough
Build speed: Fast
Applications: Form/fit testing,
Less detailed parts, Rapid
tooling patterns…

 Wide range of materials  Requires post-curing.

 Fast Build time  Overheated roller may
 High accuracy damage sheet
 durability  Limited materials (Photo
 High part complexity polymers).
 Support structures always
needed.

FUSED DEPOSITION MODELING (FDM)
 Involves melting a thermoplastic polymer (usually polyester, ABS plastic, or
casting wax) and squeezing thin filaments out of a nozzle, layer by layer, on a
building platform. As the material descends to the platform, it is immediately
hardened.
 The FDM technique relies on melting and selectively depositing a thin filament of
thermoplastic polymer in a cross-hatching fashion to form each layer of the part.
 The material is in the form of a wire supplied in sealed spools which is mounted on
the machine and the wire is threaded through the FDM head.
 The head is moved in the horizontal X and Y directions for producing each layer
through zigzag movements.

 The supporting table moves in the vertical direction and is lowered after the
completion of each layer.
 A second nozzle supplies soluble support material, if necessary, to the building

platform to prevent certain geometry from deflecting because of gravity.
 When the process finishes, the FDM part is immersed in an alkali chemical bath
to remove the support material. Depending on the machine, the nozzle can move
across a stationary platform or the nozzle may remain stationary while the
platform moves.
 Although a slight layering texture is noticeable on the surface of the parts, plastic-
based FDM machines produce very strong and durable prototypes that are ideal
for functional testing.
Working Procedure
• In FDM process, a gantry

robot-controlled extruder
head moves in two principal
directions over a table, which
can be raised and lowered as
needed.
• A thermoplastic filament is
extruded through the small
orifice of a heated die.
• The initial layer is placed on a
foam foundation by
extruding the filament at a
constant rate while the
extruder head follows a
predetermined path. https://www.youtube.com/watch?v=9cLFAI1_fmU

Working Procedure
• When the first layer is completed, the table is lowered so that subsequent layers can be
superimposed.
• In some parts, the filament is required to support the slice where no material exists beneath to
support it.
• The solution is to extrude a support material separately from the modelling material. The use
of such support structures allows all of the layers to be supported by the material directly
beneath them.
• The support material is produced with a less dense filament spacing on a layer, so it is weaker
than the model material and can be broken off easily after the part is completed.
• The layers in an FDM model are determined by the extrusion-die diameter, which typically
ranges from 0.050 to 0.12mm. This thickness represents the best achievable in the vertical
direction.
• In the x-y plane, dimensional accuracy can be as fine as 0.025mm



Technical Specification
Printing Software
Slicer Software: Cura
Technology: FDM (Fused Deposition Modeling) Software Input Formats: .STL, .OBJ, .DAE, .AMF
Build Size:210×210×205(mm3) Software Output Formats: GCode
Layer Resolution:0.05-0.3mm Connectivity: SD card; USB port (expert users
Positioning Accuracy: X/Y 0.0125mm，Z only)
0.002mm
Extruder Quantity: Single Electrical
Nozzle/FilamentDiameter:0.4 mm/1.75mm Input rating:110V/220VAC, 50/60Hz
Print Speed:20~100mm/s(suggested 60mm/s) Working Voltage:12V DC
TravelSpeed:100mm/s
Supported Materials: PLA, ABS, HIPS, Wood Physical Dimensions
Printer Dimensions:405mm×410mm×453mm
Temperature Net Weight: ~11kg
Ambient Operating Temperature:8°C-40°C
Operational Extruder Temperature:260°Cmax
Operational Print Bed Temperature:100°Cmax




A B C
Poor
adhesion
Filament evenly Insufficient
extruded extrusion
Leveled properly Nozzle too close Nozzle too high

Test Print

Abbreviation: FDM
Material type: Solid(Filaments)

Materials: ABS, Polycarbonate, Poly
phenyl sulfonite ;Elastomers
Surface finish: Rough
Build speed: Slow
Applications: Form/fit testing, Functional testing,
Small detailed parts, Presentation
models.
https://www.youtube.com/watch?v=GxLjDNrQBgs
 Durable parts can be made  Longer to build

 Minimal wastage  Low accuracy compared to SLA
 Easy handling, material  Not good for small features,
changeover and support details and thin walls.
removal.  Surface finish is rough.
 No post curing.  Support design / integration /
 Office environment friendly. removal is difficult.
 Low end, economical  Weak Z-axis.
machines.  Slow on large / dense parts.
 Easy material changeover and  Supports required on some
support removal. materials / geometries.
 Variety of materials

Applications

Materials used
ne

Materials used

Materials used

Materials for Rapid Prototyping
 Thermoplastics (FDM, SLS)
 Thermosets (SLA)
 Powder based composites (3D printing)
 Metals (SLS)
 Sealant tapes (LOM)
Examples of Rapid Prototyping Applications:
 Prototyping
Concept models
Architectural models
Plastics parts
Appliances
 Manufacturing
Implants and custom medical devices
Aerospace ducts
Pilot scale production of lab equipment
Patterns/indirect molds
Direct molds and dyes

Rapid Tooling (RT)
• The term Rapid Tooling (RT) is typically used to describe a process which either
uses a Rapid Prototyping (RP) model as a pattern to create a mould quickly or
uses the Rapid Prototyping process directly to fabricate a tool for a limited
volume of prototypes.

Conventional Tooling vs Rapid Tooling:
RT is distinguished from conventional tooling in that,
 Tooling time is much shorter than for a conventional tool.

Typically, time to first articles is below one-fifth that of
conventional tooling.
 Tooling cost is much less than for a conventional tool. Cost can be
below five percent of conventional tooling cost.
 Tool life is considerably less than for a conventional tool.
 Tolerances are wider than for a conventional tool.

Need for Rapid Tooling
o Minimize cost
o Increase productivity
o Increase dimensional accuracy
o Decrease tool time
Advantages of RT
o Quantity : large no of parts to be machined
o Design : fabrication of complex parts
o Material : for machining difficult materials
o Speed : to increase the speed of machining

Types of RT
Rapid Tooling can be broadly classified as:
1. Indirect Tooling
2. Direct Tooling
• Indirect tooling methods used RP inserts to produce moulds. Indirect or Pattern-based

Tooling approaches use master patterns to produce a mould or die, and Direct Tooling,
where the additive process builds the actual moulds. Indirect tooling methods are intended
as prototyping or pre-production tooling processes and not production methods. Most any
rapid prototyping process can yield patterns for indirect tooling.
• But direct RT methods allow injection moulding and die-casting inserts to build directly
from 3D CAD models

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LECTURE 04 : RAPID PROTOTYPING

Adib Bin Rashid

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 2

Steps in Rapid Prototyping :

 Create a CAD model of the design

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 3

Basics of model generation by rapid prototyping

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 4

• CAD Model Creation

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 5

 Conversion to STL Format:

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 6

 Slice the STL File:

DEPARTMENT OF INDUSTRIAL & PRODUCTION ENGINEERING 7

 Layer by Layer Construction:

• The fourth step is the actual construction of the part.

• Most machines are fairly autonomous, needing little human intervention.

 Clean and Finish:

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The Rapid Prototyping Wheel depicting the 4 major aspects of RP

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 It requires data acquisition through a method known as reverse engineering.

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 Photo-curing can be further divided into categories of

• single laser beam,

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Material type: Liquid(Photopolymer)

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 Achieving accuracy in  Requires post-curing.

 High part complexity  Support structures always needed.

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Material type: Powder(Polymer)

Materials: Thermoplastics: Nylon,

 No need of support structures  Rough surface finish.

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The shrinkage in laser sintering process is

The fabricated part accuracy depends on

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1. Part bed temperature

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Process parameters can be lumped into four categories:

• (3) powder-related parameters (particle shape, size and distribution, powder

• (4) temperature-related parameters (powder bed temperature, powder

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Laser, ED = P/(D*V) J/mm² ….(1)

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 Hatch spacing is usually less

 Some areas in the powder bed