PRESENTATION

ON
RAPID PROTOTYPING
 Model
 A small object,  An original, full-scale,
usually built to scale,
that represents in
detail another, often
larger object.
 
prototype
and usually working
model of a new product
or new version of an
existing product.
It is a replica of a
product as it will be
manufactured, which
may include such
details as colour,
graphics, packaging
and instructions
 definition
Rapid Prototyping (RP) can be defined as a group of
techniques
used to quickly fabricate a scale model of a part or

assembly
using three-dimensional computer aided design (CAD)

data.
These "three dimensional printers" allow designers to

quickly
create tangible prototypes of their designs, rather than

just two
dimensional pictures. Such models have numerous

uses.
 They make excellent visual aids for communicating
ideas with co-workers or customers. In addition,
. What is Rapid Prototyping

Rapid Prototyping:
Traditional manufacturing :
additive material
subtractive material
The Basic steps involved
 Create a CAD model of the design
 Convert the CAD model to STL format

 Slice the STL file into thin cross-

sectional layers
 Construct the model one layer atop
another
 Clean and finish the model

Basic steps
 CAD Model Creation: First, the object to be built is
modelled using a CAD software package. The designer
can use a pre-existing CAD file or may wish to create
one expressly for prototyping purposes. This process is
identical for all of the RP build techniques.
 Conversion to STL Format: 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 triangles. The file contains the coordinates of
the vertices and the direction of the outward normal of
each triangle. Because STL files use planar elements,
they cannot represent curved surfaces exactly.
Increasing the number of triangles improves the
approximation, but at the cost of bigger file size. Large,
complicated files require more time to pre-process and
build, so the designer must balance accuracy with
manageability to produce a useful STL file. Since the .stl
format is universal, this process is identical for all of the
RP build techniques.
Basic steps
 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. Each
RP machine manufacturer supplies their own proprietary pre-
processing software.
 Layer by Layer Construction: The fourth step is the actual
construction of the part. Using one of several techniques
(described in the next section) 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
 Basic process of RP
Three stages: pre-processing,
building, and
 post processing
C A D M odel Pre Pro ce ss R P Pro ce ss Po st Pro ce ss

S u rfa ce / S o lid G e n e ra te B u ild R e m o ve

M odel . STL file Pro to typ e S u p p o rts

in CAD C le a n
B u ild S u p p o rts
if n e e d e d S u rfa ce
Po st C u re if n e e d e d
in RP
systems
S licin g
Pa rt C o m p le te d
Rapid Prototyping Techniques
vStereoLithography (SL)
vFused Deposition Modeling (FDM)
vSelective Laser Sintering (SLS)
vLaminated Object Manufacturing
(LOM)
v3D Printing (3DP)

StereoLithography (SL)
Patented in 1986, stereolithography
started the rapid prototyping
revolution. The technique builds three-
dimensional models from liquid
photosensitive polymers that solidify
when exposed to ultraviolet light. As
shown in the figure below, the model is
built upon a platform situated just
below the surface in a vat of liquid
epoxy or acrylate resin. A low-power
highly focused UV laser traces out the
first layer, solidifying the model’s
cross section while leaving excess areas
liquid.
Next, an elevator incrementally lowers the platform into the
liquid polymer. A sweeper re-coats the solidified layer with
liquid, and the laser traces the second layer atop the first. This
process is repeated until the prototype is complete. Afterwards,
the solid part is removed from the vat and rinsed clean of excess
liquid. Supports are broken off and the model is then placed in an
ultraviolet oven for complete curing.
StereoLithography Apparatus (SLA)
  Representative:
 from 3D Systems, Inc. Application areas:


 - Prototypes for concept

 Materials:

models;
 photocurable resins
 - Form-fit for assembly
Adv. &
tests and process
Disadvantages: planning;

 Good dimensional  - Models for investment

accuracy casting, replacement of

 Good surface finish the wax pattern;
 Narrow range of materials  - Patterns for metal
 Relatively high cost spraying, epoxy
 Post curing molding and other soft
tooling
 Laminated Object Manufacturing
In this technique layers of adhesive-coated
sheet material are bonded together to form
a prototype. The original material consists
of paper laminated with heat-activated glue
and rolled up on spools. As shown in the
figure below, a feeder/collector mechanism
advances the sheet over the build platform,
where a base has been constructed from
paper and double-sided foam tape. Next, a
heated roller applies pressure to bond the
paper to the base. A focused laser cuts the
outline of the first layer into the paper
and then cross-hatches the excess area (the
negative space in the prototype)..

During the build, the excess material provides excellent support for overhangs
and thin-walled sections. After the first layer is cut, the platform lowers out
of the way and fresh material is advanced. The platform rises to slightly
below the previous height, the roller bonds the second layer to the first, and
the laser cuts the second layer. This process is repeated as needed to build
the part, which will have a wood-like texture. Because the models are made of
paper, they must be sealed and finished with paint or varnish to prevent
moisture damage.
Laminated Object Manufacturing (LOM)

  Representative:  Must be post

 from Helisys
  Materials:
 sheet material such as
paper, plastic, ceramic,
composite etc.
 Adv. &
Disadvantages:
 A relatively high speed
process
 No post curing required
 No support structure
required
 Simple to use
 The most commonly
processed immediately
 Restricted to build
complex parts
 Fire hazard
occasionally happened
  Application areas:
 - Visual
representation;
 - Concept modeling;
 - Pattern for sand
casting;

used material is only

 Selective Laser Sintering
Developed by Carl Deckard for Scanning Laser
his master’s thesis at the Mirror
University of Texas, selective
laser sintering was patented in
1989. The technique, shown in
figure , uses a laser beam to
selectively fuse powdered
materials, such as nylon, Roller
elastomer, and metal, into a
solid object. Parts are built

Support
upon a platform which sits just

Part
below the surface in a bin of
the heat-fusable powder.
A laser traces the pattern of
the first layer, sintering it
together. The platform is lowered Powder Build
by the height of the next layer cartridges Piston Chamber
and powder is reapplied.

This process continues until the part is complete. Excess powder in each
layer helps to support the part during the build.
Selective Laser Sintering (SLS)

  Representative:  Expensive running cost

 Toxic gases generated
 from DTM Corporation
  Materials:  Application areas:
 powder material such as  - Visual representation;
nylon, wax,
 - durable enough for
polycarbonate, metal,
ceramic, elastomer, etc. most functional tests;
Adv. &  - Pattern for making soft

Disadvantages: tooling, casting;

 Large variety of material 
available - Direct manufacture of
 Produced in short time metal mould;
 No additional support  - Small batch production

required
run.
 No post curing required
 Heat up powder & cool
Fused Deposition Modeling
In this technique, filaments of heated
thermoplastic are extruded from a tip Model & Support Filaments
that moves in the x-y plane. Like a
baker decorating a cake, the
controlled extrusion head deposits Heated extrusion
very thin beads of material onto the head
build platform to form the first
layer. The platform is maintained at a

Support

Part
lower temperature, so that the
thermoplastic quickly hardens. After
the platform lowers, the extrusion
head deposits a second layer upon the
first. Supports are built along the
way, fastened to the part either with Elevator & Platform
a second, weaker material or with a
perforated junction.
Fused Deposition Modeling (FDM)

  Representative:  - Slow for building a mass

part
 from Stratasys Inc.
  Application areas:
 Materials:
 - Conceptual modeling;
 thermoplastic material
such as wax, ABS plastic &  - Fit, form and functional
elastomer test;
Adv. &
 - Pattern for investment

Disadvantages: casting;
 clean, simple, easy to  - The MABS (methy
operate
methacrylate ABS)
 A good variety of material
material is particularly
 Mid range
performance/cost suitable for medical
 applications.
3d printing
 Three dimensional printing is a quick, low cost rapid
prototyping process used for concept modeling.
The system applies a thin layer of powder on a
chamber surface. The ink-jet style spray head
deposits a liquid adhesive onto the powder in a 2-
D pattern, bonding the layer to form the object.
Materials are starch or plaster based which a
fragile when handled. The process yields a
slightly rough textured surface with lower
accuracy than other popular RP systems.
 Ink jet printing comes from the printer and plotter
industry where the technique involves shooting
tiny droplets of ink on paper to produce graphic
images. RP ink jet techniques utilize ink jet
technology to shoot droplets of liquid-to-solid
compound and form a layer of an RP model

 3d printing

Companies install them in offices

near their CAD systems for concept
modeling.

a le ss co stly a n d le ss ca p a b le
va ria tio n o f R P te ch n o lo g y
3. Application cases of RP
 Common
applications of  strong models for
the RP wind
technology:
 Design
 tunnel and stress
analysis
 concept models   Tooling
  Marketing
 models for tenders,
 masters and patterns
customer feedback, for a broad range of
presentations and manufacturing
brochures processes
  Test & Analysis   Medicine
 functional testing;  artificial limbs, tools
and instruments
 Thank you
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presented by:-
 Pulkit
bajaj