Rapid Prototyping:

Introduction
and Historical Perspective
Traditional Manufacturing?

1. Removal
(subtractive)

2. Near Net Shape

or Net Shape

3. Additive
 Rapid Prototyping

CAD Rapid Prototyping

machine
Process Planning
() ()
+ Easy planning for 3D
+ Material variety
– Accuracy: layer
+ Fast turn around
thickness
 Rapid Prototyping

• Also called
– Layered Manufacturing (LM)
– Desktop Manufacturing (DM)
– Solid Freeform Fabrication (SFF)
 Parts Made by RP
Embedded copper Invar core

Internal cooling
channels S.S 316L surfaces

Polyurethane/Epoxy turbines Alumina vane

 Benefits of RP
• Build arbitrarily complex 3D geometries
• Automatic process planning, based on CAD model
• Generic fabrication machine, i.e., do not require
part-specific fixturing or tooling
• Require minimal or no human intervention to
operate
 Benefits of RP
• Visualization, verification, iteration, and
design optimization
• Communication tool for simultaneous
engineering
• Marketing studies of consumer preferences
• Metal prototypes and Tooling fabricated from
polymer parts
Application Capabilities for RP
• One-of-a-kind item or small number parts
(normally up to 3000 units)

• Shape of object in computer form

• Complex Shape and Complex Microstructures

Price Injection Molding

RP

~3000 Part number

 RP Sequence
• CAD solid model
• ‘.STL’ file
• originated from Stereolithography
• Slicing the file
• Final build file
• Fabrication of part
• Post processing
 From CAD to Part

Model Product

• geometric model • part geometry

• material • material quality
• tolerance • geometric accuracy
•... •...
 RP: from CAD to Part

Slicing

Model Product
Process
Deposition
• STL Planning
Description

Deposition
codes
Rapid Prototyping
 Rapid Prototyping:
Historical Perspective
Layered Manufacturing ?
 Layered Manufacturing ?

• Early roots of rapid mechanical prototyping

technology
– Topography
• In 1890, layered method for making a mold
for topographical relief maps
– Photosculpture
• In 1879, attempts to create exact three-
dimensional replicas of objects, including
human forms
 Topography

Layered mold relief map proposed by Blanther (1892)

 Topography

• Layered mold of stacked sheets by DiMatteo

(1974)
 Topography

• 1979, Professor Nakagawa of Tokyo

University began to use lamination
techniques to produce actual tools such as
blanking tools, press forming tools, and
injection molding tools.
• Nakagawa mentions the possibility of
complex cooling channels in injection molds
in 1985
 Photosculpture

Admiral Farragut, late 1860s, for photo-sculpture

Early Solid Freeform Fabrication

Photosculpture process using intersecting

laser beams, by Swainson (1977)
Early Solid Freeform Fabrication

Powder laser process proposed by Ciraud (1972)

Early Solid Freeform Fabrication

Herbert's photopolymer process (1982)

 Early Parts

Three early rapid prototyping parts;

from left to right by Kodama, Herbert, and Housholder
Commercial Development

Sculpture by Solid Photography process