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Conversion of a solid model of an object into layers (only one layer is shown).

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A part produced by stereolithography (photo courtesy of 3D Systems, Inc.).

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 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.
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 Layer by Layer Construction:

The fourth step is the actual construction of

the part.
RP machines build one layer at a time from

polymers, paper, or powdered metal.

Most machines are fairly autonomous,

needing little human intervention.

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 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 durability.

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 Stereolithography
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.

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PT CAM uses a
stereolithography machine
produced by 3-D Systems and
shown here:

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 Product designers want to have a

physical model of a new part or product

design rather than just a computer
model or line drawing
Creating a prototype is an integral step in design
A virtual prototype (a CAD model of the part)

may not be sufficient for the designer to

visualize the part adequately
Using RP to make the prototype, the designer
can see and feel the part and assess its merits
and shortcomings
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 Applications of rapid prototyping can

be classified into three categories:

1. Design
2. Engineering analysis and planning
3. Tooling and manufacturing

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 Designers are able to confirm their

design by building a real physical

model in minimum time using RP
Design benefits of RP:
Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors
Increased capability to compute mass

properties
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 Existence of part allows certain

engineering analysis and planning

activities to be accomplished that would
be more difficult without the physical
entity
Comparison of different shapes and styles to

determine aesthetic appeal

Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for process

planning and tool design

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 Called rapid tool making (RTM) when

RP is used to fabricate production

tooling
Two approaches for tool-making:
1. Indirect RTM method
2. Direct RTM method

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Pattern is created by RP and the

pattern is used to fabricate the tool
Examples:

Patterns for sand casting and investment

casting
Electrodes for EDM

RP is used to make the tool itself

Example:

3DP to create a die of metal powders

followed by sintering and infiltration to
complete the die

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 Small batches of plastic parts that could

not be economically molded by injection

molding because of the high mold cost
Parts with intricate internal geometries

that could not be made using

conventional technologies without
assembly
One-of-a-kind parts such as bone

replacements that must be made to

correct size for each user

 Laser cutting is just one of a number

of processes used to cut metal into

desired shapes. Other typical cutting
processes include plasma cutting,
flame or oxyfuel cutting, water jet
cutting, and even metal stamping
which competes on certain levels

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 There are many benefits to laser-cutting

service providers that directly translate to

the process end-users. Some are:
Improved parts production and reduced part

distortion as a result of the small heat affected

zones (HAZ)
Greatly reduced tool wear due to the non-contact
cutting process.
Increased saving due to more efficient utilization
of materials
Reduced inventory due to typical efficiency of
production runs.
Improved part appearance since a laser's minimal
Heat Affected Zone eliminates distortion.
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Pictures from:
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