Reducing The Reducing The Uncertainty In The Uncertainty In The Prototyping ProcessPrototyping Process

Kevin SteeleKevin SteeleRapid Design and Manufacture Rapid Design and Manufacture

CentreCentre

A Review of Rapid Prototyping Selection SystemsA Review of Rapid Prototyping Selection Systems

IntroductionIntroduction

Specification

Conceptual Design

Concept Evaluation

Manufacture

Market Need

Detail Design

TIME

InversionInversion EmpathyEmpathy

Concept Evaluation TechniquesConcept Evaluation Techniques

Competition Analysis Competition Analysis TechniquesTechniques

DFMA DFMA GuidelinesGuidelines

PROTOTYPING TECHNIQUESPROTOTYPING TECHNIQUES

CADCAD

SPCSPC

Overall AimOverall Aim

Specification

Conceptual Design

Concept Evaluation

Manufacture

Market Need

Detail Design

TIME

• Save TimeSave Time

• Reduce Reduce CostsCostsConcept Models

“Fit and Form” Models

Rapid Tooling

Business Business AspectsAspects

TIME

Company Company RestrictiRestrictionsons

Internal Internal PrejudicPrejudiceses

CommerCommercial cial ContextsContexts

Prototyping OptionsPrototyping Options

PROTOTYPING TECHNIQUESPROTOTYPING TECHNIQUES

PHYSICALPHYSICAL

L.ML.MCNCCNCMANUALMANUAL

VIRTUALVIRTUAL

MANUAL MANUAL RENDERINGRENDERING

3D 3D CADCAD

VRVR

NONENONE

• L.M = Layered Manufacture L.M = Layered Manufacture (RP/T)(RP/T)

Issues within Layered Issues within Layered ManufactureManufacture• Rapidly Growing number of Rapidly Growing number of

TechnologiesTechnologies• Growing Number of InteractionsGrowing Number of Interactions

– 25 + RP Technologies : 19 + RT 25 + RP Technologies : 19 + RT TechnologiesTechnologies

– Escalating Number of MaterialsEscalating Number of Materials

• Growing User BaseGrowing User Base– Exponential rise in the number of RP Exponential rise in the number of RP

systems in existencesystems in existence

The Process Chain The Process Chain ConceptConcept

REQUIREMENTS DEFINITION (RP&T)

CONCEPT MODELLING

3DP ThermoJetObjet Genesys

Prodigy JP5

RAPID PROTOTYPING

SLA SLS LOM FDM SANDERS

CNC DMLS Mod

ell

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M

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Vacuum Casting KeltoolInv. Casting

Sand Casting

Metal Filled Epoxy Tooling

Spray Metal ToolingP

ost

P

ost

P

rocess

es

Pro

cess

es

Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder

Mate

rials

Mate

rials

Wax Infiltration

Case Study 1: McAlpine Case Study 1: McAlpine PlumbingPlumbing• Requirements: Requirements:

Must exhibit Must exhibit waterproof waterproof propertiesproperties

• Process Chain Process Chain Used: FDM with a Used: FDM with a wax infiltrantwax infiltrant

Process Chain Used: Process Chain Used: McAlpinesMcAlpines

REQUIREMENTS DEFINITION (RP&T)

CONCEPT MODELLING

3DP ThermoJetObjet Genesys

Prodigy JP5

RAPID PROTOTYPING

SLA SLS LOM FDM SANDERS

CNC DMLS Mod

ell

ing

M

od

ell

ing

T

ech

nolo

gT

ech

nolo

gie

sie

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Vacuum Casting KeltoolInv. Casting

Sand Casting

Metal Filled Epoxy Tooling

Spray Metal ToolingP

ost

P

ost

P

rocess

es

Pro

cess

es

Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder

Mate

rials

Mate

rials

Wax Infiltration

Case Study 2: TronicCase Study 2: Tronic

• Rubber seal for Rubber seal for protecting sub-protecting sub-sea connectorsea connector

• Process Chain: Process Chain: ZP11 Powder ZP11 Powder combined with combined with elastomer elastomer infiltrantinfiltrant

Process Chain Used: Process Chain Used: TronicTronic

REQUIREMENTS DEFINITION (RP&T)

CONCEPT MODELLING

3DP ThermoJetObjet Genesys

Prodigy JP5

RAPID PROTOTYPING

SLA SLS LOM FDM SANDERS

CNC DMLS Mod

ell

ing

M

od

ell

ing

T

ech

nolo

gT

ech

nolo

gie

sie

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Vacuum Casting KeltoolInv. Casting

Sand Casting

Metal Filled Epoxy Tooling

Spray Metal ToolingP

ost

P

ost

P

rocess

es

Pro

cess

es

Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder

Mate

rials

Mate

rials

Wax Infiltration Elastomer

Infiltration

Case Study 3: GaltronicsCase Study 3: Galtronics

• Mobile Phone Mobile Phone antenna frameantenna frame

• ZP100 & ZP100 & Cyanoacrylate Cyanoacrylate Resin: Resin: UnsuitableUnsuitable

• Correct Process Correct Process Chain: FDMChain: FDM

Process Chain Used: Process Chain Used: GaltronicsGaltronics

REQUIREMENTS DEFINITION (RP&T)

CONCEPT MODELLING

3DP ThermoJetObjet Genesys

Prodigy JP5

RAPID PROTOTYPING

SLA SLS LOM FDM SANDERS

CNC DMLS Mod

ell

ing

M

od

ell

ing

T

ech

nolo

gT

ech

nolo

gie

sie

s

Vacuum Casting KeltoolInv. Casting

Sand Casting

Metal Filled Epoxy Tooling

Spray Metal ToolingP

ost

P

ost

P

rocess

es

Pro

cess

es

Wax ABS SLA Resins LOM PapersRapidSteel CastFormZP11/14Powder

Mate

rials

Mate

rials

Wax Infiltration Elastomer

Infiltration

Case Study 4: AgilentCase Study 4: Agilent

• Only Company Only Company with in-house RPwith in-house RP

• User of 3DP, User of 3DP, SLA, and SLSSLA, and SLS

• Company Company Procedures get Procedures get in the way of in the way of RP AdoptionRP Adoption

Case Studies - Case Studies - ConclusionsConclusions• Important to establish prototype Important to establish prototype

requirements before embarking on RP requirements before embarking on RP • Knowledge of Process Capability Knowledge of Process Capability

imperativeimperative

• Vital to have Vital to have understandingunderstanding of process of process relationships between RP, RT and relationships between RP, RT and MaterialsMaterials

• Business Considerations can serve as an Business Considerations can serve as an obstacle to successful RP implementationobstacle to successful RP implementation

Previous Approaches 1Previous Approaches 1

• Simple RP Simple RP Selection Expert Selection Expert SystemsSystems

• Lack depth of Lack depth of information, no information, no Process Chain Process Chain capabilitycapability

Previous Approaches 2Previous Approaches 2

• Process Chain Process Chain SelectorsSelectors

• RAPTEC, RAPTEC, PROTOOLPROTOOL

• Select Select complete complete process process chainschains

Previous Approaches 3Previous Approaches 3

• Process Chain Process Chain Configuration Configuration SystemsSystems

• CAPP, I-ViP CAPP, I-ViP RP-SelectorRP-Selector

• Design Design process process Chains from Chains from scratchscratch

Selection System Selection System DrawbacksDrawbacks• Difficulty in turning identifying Difficulty in turning identifying

model requirements and turning model requirements and turning them into a specificationthem into a specification

• Reliance on making subjective Reliance on making subjective judgements on model geometry & judgements on model geometry & requirementsrequirements

• Existing Systems do not take into Existing Systems do not take into account external influences on account external influences on design processdesign process

Proposed ModelProposed Model

Research IssuesResearch Issues• Methodology for Correct RP/T Process Methodology for Correct RP/T Process

Chain SelectionChain Selection– Structuring of Prototype RequirementsStructuring of Prototype Requirements– Understanding of the effect of external Understanding of the effect of external

influencesinfluences

• Process Capability/Materials DatabaseProcess Capability/Materials Database– Detailed Study into RP CapabilitiesDetailed Study into RP Capabilities– New Means of Structuring the InformationNew Means of Structuring the Information

• Embodiment of MethodologyEmbodiment of Methodology

Research StrategyResearch Strategy

• Company ResearchCompany ResearchEstablish Attitudes/Practices within Establish Attitudes/Practices within

PrototypingPrototypingExamine current uses of PrototypesExamine current uses of Prototypes

• Evaluate Techniques such as QFD Evaluate Techniques such as QFD and Benefit Value Analysis for RP and Benefit Value Analysis for RP Specifiaction generationSpecifiaction generation

• Design and Evaluation of SystemDesign and Evaluation of System

Thank You for Your Thank You for Your AttentionAttention