rapi prototyping

8/6/2019 rapi prototyping

1/30

Technical Seminar

Topic : Rapid Prototyping


2/30

INTRODUCTION

n Definition

n Rapid prototyping

n Stereo lithography

n Fused deposition modelingn Laminated object manufacturing

n Selective laser sintering

n Plastic or polymer parts

n Silicon rubber tooling

n Investment castingn Application of rapid prototyping

n Rapid prototyping equipments

n conclusion


3/30

What is manufacturing

process?n The word manufacture is derived from tw o Latin words

Manu meaning by hand and Factum meaning almostliterally hand mak ing

n Manufacturing is the conversion ofraw material into usable product


4/30

PROTOTYPING

RAPID


5/30

Rapid Prototyping -

DefinitionRapid Prototyping (RP) is anautomatic process formanufacturing objects directlyfrom their CAD models withoutany cutters, tools or fixturesspecific to the object geometry.

It is more appropriate to call itLayered Manufacturing or 3DPrinting or 3D Faxing.

n RP is adivide-and-conquer

manufacturing strategy.


6/30

DRAWING

PROCESS

ENGINEERING

TOOL & FIXTURE

DESIGN

MACHINING

INSPECTION

RAPID

PR

OTOTYPI

NG

CON

VENTIONAL

MACHINI

NG

CAD MODEL

COMPLETED PART

TOOL LESS ADDITIVE PROCESS TO CONVERT

CAD MODELS DIRECTLY INTO PHYSICAL PARTS

NO INTERMEDIATE

STEPS


7/30

What is Rapid Tooling ?

n Tool fabricationtechniques that use

layer wise RapidPrototypingtechnologies -directly or indirectly


8/30

Rapid prototyping

Technologies1. Stereo Lithography (SLA)

2. Fused Deposition Modeling (FDM)

3. Laminated Object Manufacturing (LOM)4. Selective Laser Sintering (SLS)

5. Direct Metal Laser Sintering (DMLS)

6. Solid Ground Curing (SGC)

7. Laser Engineering Net Shaping (LENS)


9/30

Rapid Prototyping Input

materials

n SLA - Liquid epoxy resins

n FDM - ABS plastics

n LOM - Paper and Plastic sheets

n SLS - Polyamides and Metal powders

n DMLS - Polyamides and Metal powders

n

LENS - Titanium, steel, inconel etc.,


10/30

Stereo lithography(SLA)


11/30

Part built by Stereo

lithography (SLA)


12/30

FDM (FUSED DEPOSITION

MODELLING)


13/30

FDM Applications:

Functional Modelsn Available Materials

n ABS

n ABSi

n Elastomer

n Key Part Characteristicsn ABS and ABSi closest RP

materials to engineeringthermoplastic ABS

n High Use Temperature =>200 C


14/30

FDM Systems

FDM 3000 FDM TITAN FDM VANTAGE


15/30

Part LOM(LAMINATED

OBJECT MANUFACTURING)


16/30

Laminated Object

Manufacturing (LOM)

Parts are built by cutting Paper & Plastic sheet


17/30

INVESTMENT CASTINGn WAX CASTINGS OR MODELS FROM RP PROCESS ARE

ENCAPSULATED I N CERAMICAND HEATED TO LEAVE ACAVITYWHI CH IS FILLED WITH METAL EITHER UNDER VACUUMPRESSURE OR GRAVITY

n

LEAD TIME LESS THAN 3 DAYS

n MATERIALS SUCH AS :n MAGNESIUMn ALUMINIUM

n BRONZE

n BRASSn COPPER

n BERYLLIUM CAN B E CASTED


18/30

INVESTMENT CASTING


19/30

INVESTMENT CASTING

(Indirect tooling)


20/30

INVESTMENT CASTING

PATTERN


21/30

Selective Laser-SinteringLoose

Powder

PlatformLoose Powder

Frame

Part

LaserOpticsScanner


22/30

SILICONE RUBBER MOULDINGn TIME TO BUILD RP PART : 5 TO 50 HOURS

TIME TO FINISH A PART : 2 TO 8 HOURS

TIME TO MAKE A MOULD : 1 TO 4 HOURS

TIME TO CAST A PART : 1 HOUR

n PROCESS SUITABLE FOR PRODUCING 25 TO 100PARTS


23/30

Application

0F

Rapid prototyping


24/30

Fine arts

Render showingsurface texture

Reproduction of afine detail plaque


25/30

Jewellery

+ =

Scanning strategies

Stylus 1.0mm ball Scanning speed 350mm/min

2,831,862

data points

2,225,866

data points


26/30

Medical

Hip ball

93,414 pointsTime 44mins

Hip socket

374,061 pointsTime 3hr. 45mins


27/30

Medical

Scanning strategies Stylus 0.5mm ball Stepover 0.05mm

Scanning speed 1000 mm/min.

Scan time 4hr. 7min.

206,495 data points


28/30

RAPID PROTOTYPING

EQUIPMENTS

SLA Viper si2

SLA 7000

SLA 5000


29/30

In conclusion

RP , RE and RT technologies can reduce lead-time drastically forproduct development.

Reverse engineering technologies like CMM, standalonescanning machines can help in capturing data of existingproduct and thereby modifications can be done easily.

RP(layering approach) allows very intricate parts to beproduced.

Aphysical model that can be produced directly from CAD files,can allow form, fit and function tests much earlier in the designcycle.

Prototype tooling manufacture for producing pilot batch forfunctional trials and test marketing.

New developments are going on in RP & RE technologies.


30/30

Thank You

rapi prototyping

Documents