ME711PE: ADDITIVE MANUFACTURING(PE – II)

UNIT - I
Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping,Advantages and Limitations of Rapid Prototyping,
Commonly used Terms, Classification of RP process,Rapid Prototyping Process Chain: Fundamental Automated Processes
UNIT - II
Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo
polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models
and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated
Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused
Deposition Modeling (FDM): Models and specifications,Process, working principle, Applications, Advantages and Disadvantages, Case studies
UNIT - III
Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications,Process, working principle, Applications, Advantages
and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications,Advantages and
Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT),Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification; Indirect
Rapid Tooling Methods:Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Diecasting, Sand Casting, 3D Keltool
process. Direct Rapid Tooling : Direct AIM, LOM Tools, DTM RapidTool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.
UNIT - IV
Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file
Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like
Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.
UNIT - V
RP Applications: Application - Material Relationship, Application in Design, Application in Engineering,Analysis and Planning, Aerospace Industry,
Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning
and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and
Anthropology, Visualization of Biomolecules.
SLS Materials

• Polyamide. Trade named “DuraFormTM”, this material is used to create rigid and rugged plastic parts for
functional engineering environments. This material is durable, can be machined or even welded where
required. A variation of this material is the polyamidebased composite system, incorporating glass-filled
powders, to produce even more rugged engineering parts. This composite material improves the resistance to
heat and chemicals.
• Thermoplastic elastomer. Flexible, rubber-like parts can be prototyped using the SLS. Trade named,
“SOMOS® 201”, the material produces parts with high elongation. Yet, it is able to resist abrasion and
provides good part stability. The material is impermeable to water and ideal for sports shoe applications and
engineering seals.
• Polycarbonate. An industry-standard engineering thermoplastic. These are suitable for creating concept and
functional models and prototypes, investment casting patterns for metal prototypes and cast tooling,
masters for duplication processes, and sand casting patterns. These materials only require a 10–20 W laser
to work and are useful for visualizing parts and working prototypes that do not carry heavy loads. These parts
can be built quickly and are excellent for prototypes and patterns with fine features.
SLS Materials
• Nylon. Another industry-standard engineering thermoplastic. It is one of the most durable
rapid prototyping materials currently available in the industry, and it offers substantial
heat and chemical resistance. A variation of this is the Fine Nylon and is used to create
fine-featured parts for working prototypes. It is durable, resistant to heat and chemicals,
and is excellent when fine detail is required.
• Metal. This is a material where polymer coated stainless steel powder is infiltrated with
bronze. Trade named “LaserForm ST-100”, the material is excellent for producing core
inserts and preproduction tools for injection molding prototype polymer parts. The
material exhibits high durability and thermal conductivity and can be used for relatively
large-scale production tools.
• Ceramics. Trade named “SandFormTM Zr” and “SandformTM Si”, these use zircon and
silica coated with phenolic binder to produce complex sand cores and molds for
prototype sand castings of metal parts.
Advantages
(1) Good part stability. Parts are created within a precise controlled environment. The process and materials provide for
directly produced functional parts to be built.
(2) Wide range of processing materials. A wide range of materials including nylon, polycarbonates, metals and ceramics
are available, thus providing flexibility and a wide scope of functional applications.
(3) No part supports required. The system does not require CADdeveloped support structures. This saves the time
required for support structure building and removal.
(4) Little post-processing required. The finishing of the part is reasonably fine and requires only minimal post-processing
such as particle blasting and sanding.
(5) No post-curing required. The completed laser sintered part is generally solid enough and does not require further
curing.
(6) Advanced software support. The New Version 2.0 software uses a Windows-style graphical user interface (GUI).
Apart from the basic features, it allows for streamlined parts scaling, advanced nonlinear parts scaling, in-progress part
changes, build report utilities and is available in foreign languages
Disadvantages
(1) Large physical size of the unit. The system requires a relatively large space to house it. Apart from this, additional
storage space is required to house the inert gas tanks used for each build.
(2) High power consumption. The system requires high power consumption due to the high wattage of the laser required
to sinter the powder particles together.
(3) Poor surface finish. The as-produced parts tend to have poorer surface finish due to the relatively large particle sizes
of the powders used.
 Applications
(1) Concept models. Physical representations of designs used to review
design ideas, form and style.
(2) Functional models and working prototypes. Parts that can withstand
limited functional testing, or fit and operate within an assembly.
(3) Polycarbonate (RapidCastingTM) patterns. Patterns produced using
polycarbonate, then cast in the metal of choice through the standard
investment casting process. These build faster than wax patterns and are
ideally suited for designs with thin walls and fine features. These
patterns are also durable and heat resistant.
(4) Metal tools (RapidToolTM). Direct rapid prototype of tools of molds
for small or short production runs.
https://www.youtube.com/watch?v=GnFxujCyD7
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Classification of rapid tooling
Classification of rapid tooling
 ME711PE: ADDITIVE MANUFACTURING(PE – II)
UNIT - I
Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping,Advantages and Limitations of Rapid Prototyping,
Commonly used Terms, Classification of RP process,Rapid Prototyping Process Chain: Fundamental Automated Processes
UNIT - II
Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo
polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models
and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated
Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused
Deposition Modeling (FDM): Models and specifications,Process, working principle, Applications, Advantages and Disadvantages, Case studies
UNIT - III
Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications,Process, working principle, Applications, Advantages
and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications,Advantages and
Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT),Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification; Indirect
Rapid Tooling Methods:Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Diecasting, Sand Casting, 3D Keltool
process. Direct Rapid Tooling : Direct AIM, LOM Tools, DTM RapidTool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.
UNIT - IV
Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file
Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like
Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.
UNIT - V
RP Applications: Application - Material Relationship, Application in Design, Application in Engineering,Analysis and Planning, Aerospace Industry,
Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning
and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and
Anthropology, Visualization of Biomolecules.
 Direct AIM
• A rapid tooling method developed by 3D CAD/CAM systems uses the
SLA to produce resin molds that allow the direct injection of
thermoplastic materials. Known as the Direct AIM (ACES injection
molding), this method is able to produce high levels of accuracy.
• However, build times using this method are relatively slow on the
standard stereolithography (SLA) machine.
• Also, because the mechanical properties of these molds are very low,
tool damage can occur during ejection of the part.
• This is more evident when producing geometrically more complex parts
using these molds.