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INTRODUCTION

RAPID

PROTOTYPING

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OUTLINE Basics of Rapid Prototyping(RP),

Need for RP system,

Classication of RP system,

!"ndamental fa#rication Process,

Basic Process of RP system,

Impacts of RP and its tooling in

Prod"ct $e%elopment process,

Benets of RP system,

&pplications of RP systems,

$igital and 'irt"al Prototyping

 o"rnals

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PRODUCTDEVELOPMENT

PROCESS

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PROTOT*PE

Prototype is the frst or originalexample o something that hasbeen or will be copied or

developed ; it is a model orpreliminary version.

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&+PECT+ O! PROTOT*PE

Implementation o prototype rom the

entire product or system.

 The orm o the prototype ; rom a

virtual prototype to a physical

prototype.

 The degree o the approximation o the

prototype, rom a very rough

representation to an exact application

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R&PI$ PROTOT*PIN

Rapid prototyping technologies are able to

produce physical model in a layer by layer

manner directly rom their !" models

without any tools, dies and fxtures andalso with little human intervention.

RP is capable to abricate parts #uic$ly

with too complex shape easily ascompared to traditional manuacturing

technology.

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-.* PROTOT*PE+

NEE$ O! R&PI$

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NEE$ O! R&PI$PROTOT*PIN

%nable to explore the problems, ! potential oundation to developing the

system,

%arly detection o errors,

"ecrease the costly mista$es and

development time,

Increase o possible orm, ft, unction tests,

Increasing complexity,

It gives excellent visual aids or

communicating.

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I/PORT&NT NEE$ O! RP

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CL&++I!IC&TION O! RP+*+TE/+

Li0"id #ased RP systems,

+olid #ased RP systems,

Po1der #ased RP systems.

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LI2UI$ B&+E$ RP +*+TE/+

+tereolit3ograp3y &pparat"s

(+TL),

 &olid 'round uring (&'),

&olid creation system (&&),

Rapid !ree4e Prototyping (R!P),

&olid *b+ect ltraviolet-aser Printer

(&*P).

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LI2UI$ B&+E$ RP +*+TE/+

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+OLI$ B&+E$ RP +*+TE/+ Laminated O#5ect /an"fact"ring (LO/),

!"sed $eposition /odeling (!$/),

Paper aminated Technology (PT),

/ulti-0et /odeling &ystem (/0/),

/elted %xtrusion /odeling (/%/).

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PO-$ER B&+E$ RP +*+TE/+

+electi%e Laser +intering (+L+),

$irect /etal Laser +intering

($/L+),

T3ree $imensional Printing,

Laser Engineered Net +3aping,

Electron Beam /elting Process,

"irect &hell Production asting.

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PO-$ER B&+E$ RP +*+TE/+

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!UN$&/ENT&L !&BRIC&TIONPROCE++

+"#tracti%e

&dditi%e

!ormati%e

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+UBTR&CTI'E

In a subtractive process, one starts with

a single bloc$ o solid material larger

than the fnal si1e o the desired ob+ect

and portion o the material are removed

until.

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&$$ITI'E

!n additive process is the exact reverse

in that the end product is much larger

than the material when it started ,

materials are manipulated so that they

are successively combined to orm it into

the desired shape.

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!OR/&TI'E

 The ormative process is one where

mechanical orces or restricting orms

are applied on a material so as to orm it

into the desired shape.

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Build

Prototype

B&+IC PROCE++ O! RP

Three stages: pre-processing, building,and

  post processing

RP Process Post ProcessPre Process

Generate

.STL file

Build Supports

if needed

Slicing

Remove

Supports

Clean Surface

Post Cure if needed

Part Completed

CAD Model

Surface/Solid

Model

in RP

systems

in CAD

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C&$ /O$EL CRE&TION 2irst, the ob+ect to be built is modeled using a

omputer-!ided "esign (!") sotware pac$age.

&olid modelers, such as Pro3%4'I4%%R, tend to

represent 5-" ob+ects more accurately than

wire-rame modelers such as !uto!", and will

thereore yield better results.

 This process is identical or all o the RP build

techni#ues.

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CON'ER+ION TO +TL !OR/&T 

 To establish consistency, the &T

(stereolithography, the frst RP techni#ue)

ormat has been adopted as the standard o

the rapid prototyping industry.

 The second step, thereore, is to convert the

!" fle into &T ormat. This ormat

represents a three-dimensional surace as an

assembly o planar triangles.

&T fles use planar elements, they cannot

represent curved suraces exactly. Increasing

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CON'ER+ION TO +TL !OR/&T 

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CON'ER+ION TO +TL !OR/&T 

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&"to $es6 

  6.2ile menu-save copy !s

  7.&elect &T rom the types drop down

  5.hec$ options-choose high(or #uality

surace)  8.lic$ save.

C&TI&

  6.&elect &T command

  7./aximum seg to 9.96:mm  5.&elect the model, then select yes

  8.&elect %xport, o$.

CON'ER+ION TO +TL !OR/&T 

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 +LICE T.E +TL !ILE 

In the third step, a pre-processing program

prepares the &T fle to be built.

 The pre-processing sotware slices the &T

model into a number o layers rom 9.96 mm

to 9. mm thic$, depending on the build

techni#ue.

 The program may also generate an auxiliarystructure to support the model during the

build. &upports are useul or delicate

eatures such as overhangs, internal cavities,

+LICE T.E +TL !ILE

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 +LICE T.E +TL !ILE 

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L&*ER B* L&*ER CON+TRUCTION

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L&*ER B* L&*ER CON+TRUCTION

 The ourth step is the actual construction

o the part.

RP machines build one layer at a time

rom polymers, paper, or powdered metal.

/ost machines are airly autonomous,

needing little human intervention.

L&*ER B* L&*ER CON+TRUCTION

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L&*ER B* L&*ER CON+TRUCTION

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CLEAN AND FINISH 

 The fnal step is post-processing. Thisinvolves removing the prototype rom the

machine and detaching any supports.

&ome photosensitive materials need to be

ully cured beore use

Prototypes may also re#uire minor cleaning

and surace treatment.

&anding, sealing, and3or painting the model

will improve its appearance and durability.

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CLEAN AND FINISH 

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IMPACT OF RAPID PROTOTYPING AND TOOLING IN

PRODUCT DEVELOPMENT 

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CONT,..

 Time saving (!" < !%) In Rapid Prototyping the di=erent design and

manuacturing activities are carried out

conc"rrently. &o there is a possible to

compress the over all product development

time

It can greatly reduce the TI/%-T*-/!R>%T

Reducing the part count and thereby

reducing assembly.

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CONT,..

 The product designers can increase partcomplexity with little signifcant e=ects on

lead time and cost.

 The manuacturer can reduce the labour

content o machining3casting.

It can greatly reduce material waste, waste

disposal cost.

 The main savings are in costs.

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BENEFITS OF RP

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DIRECT BENEFITS

!OR PRO$UCT $E+INER+

  6.an increase the part complexity with littlesignifcant e=ects.

  7.an reduce the part count.

  5./inimi1ing the time consume to discussionand evaluation o manuacturingpossibilities.

!OR TOOL &N$ /&NU!&CTURIN ENINEER+

6.The main savings are cost

7.an minimi1e design and manuacturing andverifcation o tooling.

5.an reduce the part count and thereorereducing assembly.

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INDIRECT BENEFITS

FOR MARKETING  1.It greatly reduces the TIME-TO-MARKET

  2.Can easily expand distribution and quickly

enter foreign markets.

  FOR CONSUMERS

1.The customers can buy products which meet

more closely individual needs and wants.

2.Consumer can buy products at lower prices.

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 APPLICATIONS

 Aerospace Automotive

Biomedical

Jewelry

Coin

Tableware

Consumer Electronics

 Architecture

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 AEROSPACE (8.2%)

AUTOMOTIVE(317%)

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 AUTOMOTIVE (31.7%)

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BIOMEDICAL (8.8%)

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CONSUMER PRODUCTS (18.4%)

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 ACADEMIC (8.6%)

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 ARCHITECTURE

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DIGITAL PROTOTYPING

The digital prototyping gives virtual explore to a

complete product before it built, for conceptual

design, engineering, manufacturing, sales and

marketing departments. DP use to design, iterate, optimize, validate and

visualize their products.

It creates photorealistic rendering and animations

of products prior to manufacturing.

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CONT,.

Digital prototyping goes beyond simply creating

product design in 3D.

For product development team

1.It gives a way to access to operation of moving

parts, to determine the product will fail or not.

2.Also we can see how the various product

components interact with subsystems.

3.It reduces the number of physical prototype

thereby reducing cost and time.

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 VIRTUAL PROTOTYPING

It is the technique in the process of product

development.

 Virtual prototyping involves CAD/CAE software to

validate a design before committing to make a

physical prototype.

 A virtual prototype intended to producing an initial

concept of design.

The virtual prototype predict the performance prior

to constructing physical prototype.

VIRTUALPROTOTYPING

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 VIRTUAL PROTOTYPING

Using VP ability to explore a wide range of design

alternative leads to improvements in performance and

design quality. (Mechanical motion, assembly and

matting etc,..

Using VP time to market gets reduced sustainly

because the VP much faster than physical prototype.

JOURNALS

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JOURNALS

Rapid Prototyping Journal – Emerald insight

International Journal of Rapid Manufacturing –

Inderscience Publisher

 Virtual and Physical Prototyping – Taylor and Francis

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