1.

What is Rapid Prototyping

Rapid Prototyping: Traditional manufacturing:

additive material subtractive material
 1.1 Characteristics of RP
 A technology that produces models and
prototype parts from 3D CAD model data, CT
and MRI scan data, and model data created from
3D object digitizing systems
 RP systems join together liquid, powder and
sheet materials to form parts

Layer by layer, RP machines fabricate plastic,

wood, ceramic and metal objects
RP also known as Solid Freeform Fabrication (SFF)
or Layer Manufacturing (LM)
1.2 Basic process of RP
Three stages: pre-processing, building, and
post processing

CAD Model Pre Process RP Process Post Process

Surface/Solid Generate Build Remove

Model .STL file Prototype Supports

in CAD Build Supports Clean Surface

if needed
Post Cure if needed
in RP
systems Slicing
Part Completed
1.3 Benefits of RP
Improved product quality
Shorten time to market & RP enable more design
reduced development cost
iterations in a given time
THE COST OF CHANGE
PHASE COST

Conceptual modeling $10

Detail design $100
3D visualization of product
Prototype/test $1,000
designs
Manufacturing $10,000 Esure that customers have
Product release $100,000 a clear understanding
“A picture is worth a
Source: Wohlers Associates thousand words; a model is
worth a thousand pictures.”
2. Common types of RP

 The first RP system was introduced in 1988

 Common types of RP technologies now:

- StereoLithography (SL)

- Fused Deposition Modeling (FDM)

- Selective Laser Sintering (SLS)

- Laminated Object Manufacturing (LOM)

- 3D Printing (3DP)
2.1 Stereo-Lithography (SL)

1. The elevator lowered by 1 Scanning Laser

layer deep; Mirror
2. The Blade sweep across Re-coating
the vat, apply an even layer Blade
Cured resin
of resin on top of the part; to form model
3. As the laser beam strikes
the resin surface, the liquid
resin is hardened to a solid
plastic;
4. Loop through the three
Liquid Resin
steps to cure a new layer.
Stereo-Lithography Apparatus (SLA)
 Representative:  Application areas:
from 3D Systems, Inc. - Prototypes for concept
models;
 Materials:
- Form-fit for assembly
photocurable resins tests and process
 Adv. & Disadvantages: planning;
 Good dimensional - Models for investment
accuracy casting, replacement of
the wax pattern;
 Good surface finish
- Patterns for metal
 Narrow range of spraying, epoxy molding
materials and other soft tooling
 Relatively high cost
 Post curing
2.2 Fused Deposition Modeling (FDM)

Model & Support Filaments 1. Extrusion head and

elevator move to start
Heated extrusion position;
head 2. The head extrude
layer of support;
Part

3. The head extrude

layer of model;
4. Loop through the three
Elevator & Platform steps to build the next
layer.
Fused Deposition Modeling (FDM)
 Representative:
from Stratasys Inc.
 Materials:
thermoplastic material such
as wax, ABS plastic &
elastomer
 Adv. & Disadvantages:
 clean, simple, easy to operate
 A good variety of material
 Mid range performance/cost
 Relative low accuracy
 Poor strength in vertical
direction
- Slow for building a mass part
 Application areas:
- Conceptual modeling;
- Fit, form and functional
test;
- Pattern for investment
casting;
- The MABS (methy
methacrylate ABS)
material is particularly
suitable for medical
applications.
2.3 Selective Laser Sintering (SLS)

1. Piston of the part built

chamber lower by one layer; Scanning Laser
Mirror
2. Piston of powder cartridges
raise up;
3. Roller spread powder
evenly over the built Roller
surface;
4. Laser beam scan over the
top of the part, melting the
powder and fuse it to the
previous layer;
Powder Build
5. Loop through the four steps cartridges Piston Chamber
to build the next layer.
Selective Laser Sintering (SLS)
 Representative:
from DTM Corporation
 Materials:
powder material such as nylon,
wax, polycarbonate, metal,
ceramic, elastomer, etc.
Adv. & Disadvantages:
 Large variety of material available - Pattern for making soft
 Produced in short time
 No additional support required
 No post curing required
 Heat up powder & cool down part
 Smoothness of surface restricted
 Expensive running cost
 Toxic gases generated
 Application areas:
- Visual representation;
- durable enough for most
functional tests;
tooling, casting;
- Direct manufacture of metal
mould;
- Small batch production run.
2.4 Laminated Object Manufacturing
(LOM)
1. The sheet material is stretched
from the supply roller to the
take-up roller;
2. The heated laminated roller
passes over the sheet bonding
it to the previous layer;
3. Laser cuts the profile of that
layer and hatching the excess
material for later removal;
4. Loop through the three steps
to form a new layer.
Laminated Object Manufacturing (LOM)
 Representative:
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 used
material is only paper
 Must be post processed
immediately
 Restricted to build complex
parts
 Fire hazard occasionally
happened
 Application areas:
- Visual representation;
- Concept modeling;
- Pattern for sand casting;
2.5 3D Printing (3DP)
Companies install them in offices
near their CAD systems for concept
modeling.

less costly and less capable

variation of RP technology
3. Application cases of RP

Common applications strong models for wind

of the RP technology: tunnel and stress
 Design analysis
concept models  Tooling
 Marketing
masters and patterns
models for tenders, for a broad range of
customer feedback,
presentations and manufacturing
brochures processes
 Test & Analysis  Medicine
functional testing; artificial limbs, tools and
instruments
 4. Rapid Tooling Making (RTM)
 INDIRECT RPM: Pattern created by RP used to fabricate
tool
- RP-fabricated part as master in making silicon-rubber
mold (subsequently used as production mold)
- RP patterns to make sand molds for sand casting
- Fabrication of patterns of low-melting pt. materials for
Investment casting

 DIRECT RPM: RP used to make the tool itself

- 3D printing to create die geometry in metallic powders
(followed by sintering & infiltration)
4. Rapid Tooling Making (RTM)

 low volume (from

tens to hundreds)
- Soft Tooling

 Intermediate (from
hundreds to
thousands)
- Metal filled Epoxy
Tooling
- Powdered Metal Aluminum-filled epoxy mold,
Tooling SL master, and molded
thermoplastic parts