UNIT – 1

Basic Principles and Development

of AM Technology

Presented By
DHANURAJU H D

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Contents:
Rapid Prototyping Technologies
Laminated Object Manufacturing

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 Rapid Prototyping
The first form of creating layer by layer a three-
dimensional object using computer-aided design (CAD) is
rapid prototyping.
Developed in the 1980’s for creating models and
prototype parts.
Rapid prototyping is one of the earlier additive
manufacturing (AM) processes.

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Rapid Prototyping
Rapid prototyping was termed because of the process this
technology was designed to enhance or replace.
Manufacturers and product developers used to find
prototyping a complex, tedious, and expensive process
that often hinder the developmental and creative phases
during the introduction of a new product.
RP was found to significantly speed up this process and
thus the term was adopted.

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Data flow in rapid prototyping

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 Steps in RPT:
1.CAD MODEL CREATION: First the object to be build is
modelled:
• using a CAD software package
• Or by using a laser scanner or a Coordinate Measuring Machine
(CMM). (”Reverse engineering””)
2. CONVERSION TO STL FORMAT:
The standard data interface between CAD software and the machine is
the STL-format (Stereo lithography). An STL-file approximates the
shape of a part using triangular facets. Small facets produce a high
quality surface. Since the STL format is universal, this process is
identical for all of the RP build techniques.
3. SLICE THE STL FILE:
The program may also generate an auxiliary structure to Support the
model during the build.
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4. LAYER BY LAYER CONSTRUCTION:
The fourth step is the actual construction of the part. Using one of
several techniques (described later) RP machines build the model
layer by layer.
The material´s initial states are:
• Liquid
• Solid or
• Powder
5.CLEAN AND FINISH:
• Removement of the part from the machine
• Detaching any supports
• After cure (some photosensitive materials)
• Cleaning and surface treatment
• Possible painting etc.
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 Types of rapid prototyping

Stereo lithography  

Selective laser sintering

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Laminated object manufacturing 

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Applications of rapid prototyping
Rapid tooling
Aerospace and marine
Architecture
Fashion and jewellery
sculptures

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Laminated object manufacturing (LOM)

1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning

prism. 5 Laser unit. 6 Layers. 7 Moving platform. 8 Waste.
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Laminated Object Manufacturing (LOM) is a process that
combines additive and subtractive techniques to build a part
layer by layer.
A carbon dioxide laser cuts the material to the shape of each
layer given the information of the 3D model from the CAD
and STL file.
Sheet is adhered to a substrate with a heated roller
Laser traces desired dimensions of prototype
Laser cross hatches non-part area to facilitate waste removal
Platform with completed layer moves down out of the way
Fresh sheet of material is rolled into position
Platform moves up into position to receive next layer
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Laminated Object Manufacturing Features

Inexpensive – low material cost

Print resolution is lower than other methods
Materials
–Paper (most common), plastics, composites, metal,
ceramics
Support material
–Same material can be used as support

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Sample Fabricated Objects

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The Advantages Of LOM
This process are the low cost
No post processing and supporting structures
required
No deformation or phase change during the process,
The possibility of building large parts.

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The Disadvantages Of LOM
The fabrication material is subtracted thus wasting it
Low surface definition
 The material is directional dependent for
machinability and mechanical properties
Complex internal cavities are very difficult to be built.

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THANK YOU

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