POWDER BASED RAPID

PROTOTYPING

Presented To:
Engr. Misbah Niamat
Group Members

 ABDUL HANNAN 2016-BT-MECH-709

 MUDASSIR HUSSAIN 2016-BT-MECH-710

 MUHAMMAD SAAD 2016-BT-MECH-713

 AZHAR U DIN 2016-BT-MECH-718

 MUHAMMAD ASIF 2016-BT-MECH-721

 ABDUL HANNAN
2016-BT-MECH-709
CONTENTS:

• DEFINATION
• TYPES
• WORKING PRICIPAL
• ADVANTAGE & DISADVANTAGE
• PROBLEM WITH RAPID PROTOTYPING
DEFINATION
Rapid Prototyping (RP) is two decade old
technology to quickly produce tangible objects
directly from a 3D CAD model and is being used
to shorten and simplify the product development
cycle for many applications including aerospace,
automobile and home appliances etc.
THEORYOF POWDER BASED RAPID
PROTOTYPING

• It involves adding material successively, in layers, to create a solid of a predefined

shape.
• Over the years, RP has evolved from producing prototypes for form, fit and
functional testing to producing final end products for functional use.
• Since the presentation of first commercial application in last decade, a large
number of processes have been developed.
• Present day commercial systems use various materials that range from polymers,
metals, metal-polymer composites, ceramics and sand.
• As the growing number of new applications constantly motivate in developing
new materials, it is essential to study the feasibility of new materials suitable for
layered manufacturing.
• The properties of the material, particle size, fusibility of powder particles
and thermal and optical characteristics are the bottlenecks in achieving
required mechanical properties, feature resolution, accuracy and surface
quality of the end product.
• In this paper, recent developments in materials for powder based layered
manufacturing is reviewed and emphasize is given on issues and challenges
in developing new materials and methods to meet high standards of part
quality.
• Also recent research and accomplishments in processing bio-materials,
heterogeneous materials and direct tools are discussed.
MUDASSIR HUSSAIN
2016-BT-MECH-710
Types of Powder Based RP
• SELECTIVE LASER SINTERING

• THREE DIMENSIONAL PRINING

Selective Laser Sintering

Selective Laser Sintering

SELECTIVE LASER SINTERING
MUHAMMAD SAAD
2016-BT-MECH-713
THREE DIMENSIONAL PRINING

• This RP technology was developed at Massachusetts Institute of Technology.

Three-dimensional printing (3DP) builds the part in the usual layer-by-layer
fashion using an ink-jet printer to eject an adhesive bonding material onto
successive layers of powders.
• The binder is deposited in areas corresponding to the cross-sections of the solid
part, as determined by slicing the CAD geometric model into layers.
• The binder holds the powders together to form the solid part, while the
unbonded
• Powders remain loose to be removed later.
• While the loose powders are in place during the build process, they provide
support for overhanging and fragile features of the part.
 THREE DIMENSIONAL PRINING
• When the build process is completed, the part is heat treated to
strengthen the bonding, followed by removal of the loose
powders. To further strengthen the part, a sintering step can be
applied to bond the individual powders.
• The part is built on a platform whose level is controlled by a
piston.
(1) A layer of powder is spread on the existing part-in-process.
(2) An ink-jet printing head moves across the surface, ejecting
droplets of binder on those regions that are to become the
solid part.
(3) When the printing of the current layer is completed, the
piston lowers the platform for the next layer.
THREE DIMENSIONAL PRINING
THREE DIMENSIONAL PRINING
 AZHAR U DIN
2016-BT-MECH-718
Powder based RP systems

• SLS
• 3DP
• LENS
• EBM
• SMS
• MJS
WORING PRINCIPAL
WORING PRINCIPAL
 ADVANTAGE

• More material choice

• Low heat effect on raw powder
• Relative easy to remove small feature
• Relative easy to remove material
• Material trapped in the scaffold
• Easy to achieve scaffold feature
DISADVANTAGES

• Material trapped into small inner holes is impossible to be

removed
• Bio degradable material maybe will degrade in the chamber
• Limited b the development of polymerizable and bio
compatible
• High heat effect on raw material
• Difficult to change material without manufacture co-operation
MUHAMMAD ASIF
2016-BT-MECH-721
PROMBLE WITH RAPID
PROTOTYPING
 The principal problems with current RP technologies include:
• part accuracy.
• limited variety of materials.
• Mechanical performance of the fabricated parts.
 Several sources of error limit part accuracy in RP systems:
• Mathematical
• Process related
• material related
• Mathematical errors include approximations of part surfaces
used in RP data preparation and differences between the
slicing thicknesses and actual layer thicknesses in the physical
part.
PROMBLE WITH RAPID PROTOTYPING

• The latter differences result in z-axis dimensional errors. An inherent limitation in the
physical part is the steps between layers, especially as layer thickness is increased,
resulting in a staircase appearance for sloping part surfaces.
• Process-related errors are those that result from the particular part building technology
used in the RP system. These errors degrade the shape of each layer as well as the
registration between adjacent layers.
• Process errors can also affect the z-axis dimension. Finally, material-related errors include
shrinkage and distortion. An allowance for shrinkage can be made by enlarging the CAD
model of the part based on previous experience with the process and materials
 PROMBLE WITH RAPID
PROTOTYPING
• Current rapid prototyping systems are limited in the variety of materials
they can process. For example, the most common RP technology,
stereolithography, is limited to photosensitive polymers.
• In general, the materials used in RP systems are not as strong as the
production part materials that will be used in the actual product.
• This limits the mechanical performance of the prototypes and the
amount of realistic testing that can be done to verify the design during
product development.