trends in the domain of rapid rototyping: a … · trends in the domain of rapid ... an alternative...

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Int. J. Mech. Eng. & Rob. Res. 2014 Manu Srivastava et al., 2014

ISSN 2278 – 0149 www.ijmerr.com

Vol. 3, No. 3, July, 2014

© 2014 IJMERR. All Rights Reserved

Review Article

TRENDS IN THE DOMAIN OF RAPIDROTOTYPING: A REVIEW

Manu Srivastava*1, Utkarsh Singh1 and Ramkrishna Yashaswi2

*Corresponding Author: Manu Srivastava � [email protected]

RP answers the need of green manufacturing which is the need of hour in the manufacturingsector. A large number of commercially viable RP techniques are available in the market today.This paper attempts to introduce and review the newer RP technologies. It summarizes theapplications of different commercial RP technologies available. It finally recognizes the currentchallenges in this field and suggests probable solutions based on extensive literature survey.

Keywords: RP, SLS, SLA, 3DP, SDM, LENS, FDM, RP classification, RP applications

INTRODUCTION

In product design, prototyping is an impera-tive final step. Prototyping requires design,fabrication and testing of final product design.This practice started with manual prototypingthen extended to prototyping with soft curvesand presently prototyping is done with theaid of computers and is called rapidprototyping. RP/LM is accomplished by layer-on-layer material deposition. This startedduring early 1980s with massiveimprovement in CAD/CAM technologies.

The current trend is the directmanufacturing of physical objects startingfrom 3D CAD models without any classicaltools. This is termed rapid prototyping, solidfreeform fabrication, layered manufacturing,

1 Netaji Subhas Institute of Technology, New Delhi.2 Institute of Management Technology, Ghaziabad.

green manufacturing which are different

names for this automatic prototyping

(Debasish Dutta et al., 2001). Advent of RP

is a watershed event similar to advent of CNC

tools almost 3 decades ago (John Michael

Brock et al., 2012).This marks an era of

introduction of flexible automation. This

process tremendously reduces the design

cycle time especially for intricate and

complicated jobs.

Despite this tremendous growth in this

field, there are numerous challenges to be

dealt in this field. While outlining the problems

in RP applications; this paper also highlights

the applications.

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WORKING STEPS REQUIREMENTS

1. Geometric modeling

2. Data transfer and CAD interface

3. Slicing

Layered Manufacturing Processes (On basis of raw material state in compliance with Kruth Classification)

Gaseous

Chemical Reaction LCVD

Liquid Solid

Paste

Paste Polymerizatio

n Process

Wire

Multi Component Powder

Foil

Fused Layer Modelling & Ballistic Part

Manufacturing

3D Printing (Topograph

y

Selective Laser

Sintering

Solid Foil Polymerizati

on

Layered Laminate

d

Heat Thermal

Polymerization

Lamp Solid Ground Curing

Light of One

frequency

Laser Beam Stereo

lithography

Holographic interference solidification

4. Merging

5. Building the model

6. Starting the machine

7. Final post curing and finishing works

CONVENTIONAL CLASSIFICATION

Figure 1: Conventional Classification of RP Processes

An alternative approach to classification is suggested by D.T. Pham, R.S. Gault

Rapid Prototyping

Addition of Material

Removal of Material

Solid Sheet

Discrete Particles

Liquid

Bonding of sheets using adhesives

Bonding of sheets using

light

Joining of Particles

using Binder

Fusing of particles using

Laser Solidification of Molten Material

Solidification of a Liquid Polymer

Solidification of Electro set

Fluid

Layer by

Layer Point

by Point

Holographic Surface

Layer by Layer

Point by Point

Figure 2: Alternative Classification of RP Processes

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RAPID PROTOTYPINGTECHNIQUES

Stereo Lithography

It is a rapid prototyping technique thatinvolves photo polymerization that draws orprints on a photo curable resin, the crosssection of a model. This is a recent techniquethat attracted much attention because of itsability to make wide range of products withhigh accuracy. However, the dimensionalaccuracy produced is not better than

Figure 3: Stereo Lithography Apparatus

Laser source Layered part

Building platform set to move in vertical direction

Liquid polymer

Laser beam

Sweeper for leveling the current layer

Elevator for vertical motion

X-Y scanning mirror

Selective Laser Sintering

A freeform, additive manufacturing processthat uses laser on power beds to create 3-Dmodels. Its starting point is a 3-D CAD modelof part geometry out of which 2-D stack oflayers are derived which represent the part.A laser spot is created by scanning over thecross sectional area to create each layer,which results in sintering, melting andbonding particles in a lamina. The same

conventional machining processes (H S Choet al., 2000). SLA fabricates parts withoutintermediate tooling, directly from a CADmodel, in the opposite direction to gravity.Support structure is required to hold thestacked layer and resin during the fabricationprocess. The stair -stepping effect occurs bystaking layers when fabrication on an inclinedsurface (Ho-Chan Kima and Seok-Hee Lee,2005).

process is repeated so that entire stack of 2-D layers is created and bonding takes placeto form the original 3-D CAD solid model (EO Olakanmi, 2013).

Electron Beam Melting

It is an additive manufacturing process, whichforms a 3D object based on a computermodel by utilizing an electron beam to meltalloyed metal powder layer by layer. This

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technique unlike conventional techniques,anticipates microstructure and properties ofEBM produced material. It is emerging as amethod for production of orthopedic devices

Laser

Sintered part

Powder bed

Levelling roller

Powder feed supply

X-Y scanning mirror

Laser beam

Platform and piston arrangement for vertical motion

with various material, including Co-Cr-MoAlloy (R S Kircher et al., 2009).The parts arebuild up in a vacuum chamber. Later the partsare cleaned by conventional techniques

Figure 4: SLS Machine Setup


It is an additive manufacturing process, whichforms a 3D object based on a computermodel by utilizing an electron beam to meltalloyed metal powder layer by layer. Thistechnique unlike conventional techniques,anticipates microstructure and properties of

EBM produced material. It is emerging as amethod for production of orthopedic deviceswith various material, including Co-Cr-MoAlloy [32].The parts are build up in a vacuumchamber. Later the parts are cleaned by con-ventional techniques

Figure 5: Electron Beam Melting Setup

Hopper

Material released from hopper

Support material

Electron beam

Piston arrangement for vertical motion

Work piece layer formation

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Solid Ground Curing

It is a process is suitable for building parts inbatch, with different dimensions andgeometry. Although problems like quality,material properties and accuracy limit the

application of the prototypes. However themethod offers very high fabrication rate withadequate accuracy, complexities lie highaccusation rate and operating cost are thebiggest hurdles.

UV lamp with shutter

UV rays

Masked plate

Liquid Polymer

Base

Wax

Figure 6: Solid Ground Curing Process

Laser Stereo Lithography

A wide variety of material can be processedby high power laser. It uses ultraviolet laseras a source when applied to organiccompounds in a conventional process. In thetraditional approach the process of fabricationand development of models allow curing ofpart by exposing to UV light, leading toformation of 3D object.

Holographic Interference

Solidification

The entire surface is solidified by exposingthe resin to holographic image. The image is

obtained from the CAD model but not in termsof slices. It also has still not been commer-cialized.

Laser Engineered Net Shaping

It is a freeform fabrication process. It involvesfully dense 3D shapes from laser processingof ?ne powders, directly from a design model.The LENS process makes near net shapedcomplex prototypes, leading to reduction inmachining and time cost. The LENS processcan be used to deposit a variety of metalsand alloys, such as 316 stainless steel,titanium alloys and H13 steel nickel-basesuper alloys (J N DuPont, 2003).

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Figure 7: Lens Setup

Laser beam

Focused lens Concentrated laser

Powder delivery nozzle

Work piece

Melt pool

Base

Figure 8: Shape Deposition Modelling

Support deposition

Embedding another component

Shaping the part

Shaping of the support

Part deposition

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Shape Deposition Modelling

It creates metal parts with incrementaldeposition of metal and removal of materialas well. It adds the benefits of SFF and CNC.It produces parts with poor surface quality.The non-horizontal and vertical surfacesexhibit stair step effect. The mechanicalproperties are critical to layer boundarieswhich are a potential source of defect. Tosolve these problems mold SDM wasdeveloped which can build complex shapedparts. However, it uses CNC milling to shapethe surfaces effected by stair step effect.

Since the product is monolithic so noboundary layers are there I end product, thisis in spite of the fact that the mold is built inlayers (A G Cooper et al., 1999).

Three Dimensional Printing

It involves the creation of 3D object bydepositing powder with the help of a liquidbinder. It is a very versatile process whichcan make variety of complex models withdifferent kinds of material. They have verylow cost, high speed and wide application

Figure 9: 3D Printing

Machine control unit

Inkjet print heads

Part

Leveling roller

Support powder

Platform along with piston for vertical movement

Electro Setting

Conductive Material like aluminum is used.After printing of all the layers, stacking is doneand they are then immersed in electro settingfluid. The fluid in between the electrodessolidifies to form the part. Once completedand drained, the unwanted material istrimmed. The advantages of this technologyis part density, hardness, compressibility andother factors are controllable via appropriatevalue of current and voltage. The raw materialare silicon, rubber, epoxy or polyurethane.

Laser-Assisted Chemical Vapor

Deposition

Technique using gas phase conversion tosolid structure with the help of pyro lyticprocess. This technique uses a laser beamfocused perpendicular to the substrate inorder to make sure deposition take place inthe heated localized region. The laser power,pressure have considerable influence on thegrowth rate, bulk properties of fibre anddiameter as well.

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Desktop Milling

Instead of gradually building up of material,the work piece is created like n traditionalmachining. Since there is no deformation dueto shrinkage, hence higher dimensionalaccuracy can be achieved. Any CNCmachine can be used to make products frominexpensive material.

Fused Deposition Modeling

It is a rapid prototyping technique of genera-ting 3D objects from CAD models. In this ABS

plastic is extruded layer by layer from atemperature controlled head. The first stepis creation of a 3D model with any availableCAD package. The part is then converted toSTL format and then transferred to FDMQuick slice software. The part is reduced toa set of triangles by tessellation. The primaryadvantage is that even the most basiccomponent can be exported via any CADsystem. However the resolution of the part islost due to triangles and not splines and arcs.

Figure 10: Fused Deposition Modelling Setup

Filament goes into the extruder

Filament spool

Drive wheels

Liquefier along with a heater block to melt the filament

Nozzle tip set to move in the plane of work piece – layer formation


Ballistic Particle Manufacture

In this technique, molten material in form ofstream is ejected from a nozzle and laterseparates into droplets and cold weldingoccurs to form the parts. The stresses canbe reduced within the part if the substrate isrough and thermal contact between them isincreased. The choice of stream depends on

the application, can be either continuous ordrop-on-demand. The stream is excited by apiezoelectric transducer with a frequency of60 Hz. Temperature, change carried by thedroplets and velocity of droplets characterizethe part. The resolution of the droplets arearound 50-100 micrometer. It advantages arecheap and eco-friendly, and produce finegrain structure.

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Solid Foil Polymerization

The part is built up of semi-polymerized foilsand on UV light exposure, solidification takesplace and bonding takes place to the previouslayer. Upon illumination of the cross-slide, anew foil can be applied. The unwantedmaterial acts as support and can be removedlater.

Laminated Object Manufacturing

It is a robust and cost effective rapid prototy-ping technology with a variety of application.For examples in sand casting, ceramics

processing and investment casting show howa reduction of cycle times and process stepscan be achieved. The LOM equipment andprocess were designed to produce parts frompaper. Using a modified LOM machineceramic parts may also be manufacturedwhere a computer controlled laser is used tocut through the ceramic. The cutting profileis generated by the slicing of the solid model.The process is repeated layer by layer tocomplete the solid object. Though thisprocess leaves a lot of scrap but buildingspeed is 5-10 times compared to otherprocesses.

Figure 11: Laminated Object Manufacturing Process

Laser beam

Current layer


Laser

Material supply

Mirror

X-Y moving optical head

Previous layer

Beam Interference Solidification

The process employs two laser beamsoperating with different frequencies andmounted such light emitted are at rightangles, which then fall on resin kept in atransparent vat and polymerization takesplace, the liquid is exercised cited tometastable state and then the secondincident beam is polymerized to excite the

resin. This isn't a commercial process andexperiences many technical difficulties.

Three Dimensional Welding

It uses a robot with arc welding to on a simpleshaped platform that may be converted intocomplex structure. The products here are notbuilt using sliced CAD model. A relatively highresolution can be obtained. The critical thing

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here is, because of no feedback, prototypehas a tendency to melt due to heatgeneration. Hence thermopiles are used toset up a feedback control system and controlthe temperature.

Gas Phase Deposition

In here, the reactive gas is either decom-posed to heat or light. The decomposed solidthen forms the part by sticking to thesubstrate. No commercial models areavailable yet. It is of three different types:

i. Selective Area Layer Deposition-Thesolid component is used to make thepart. The parts can be constructed canbe from carbon, silicon, carbides andsilicon nitrides.

ii. Selective Area Laser Deposition VaporInfiltration)-It spreads a covering ofpowder for each layer.

iii. Selective Laser Reactive Sintering - Asolid part of silicon nitride or carbide isformed by reaction between the gas andthe layer of powder..

Spatial Forming

This process is used to produce parts withhigh precision ceramic pigmented organic'ink' is used to cure the layer with UV light ona ceramic substrate. UV light is used to curethe layer and the process is repeated, untilentire part is finished. 20% shrinkage in sizeoccur due to sintering process.

Ultrasonic Additive Manufacturing

It is a layered type freeform fabrication pro-cess. It uses of low amplitude mechanicalvibrations with high frequency, which inducesstatic as well as oscillating shear forces whichproduces elastic-plastic deformation on work.This permits atomic diffusion to occur andtends to break up and disperse aluminumoxide. It is a solid-state fabrication processthat combines layered manufacturing techni-ques and ultrasonic seam welding to form asolid freeform object. It can fabricate laminatemetal parts by welding of layers to earliermaterial, the profile of every layer is createdby contour milling. The process has greatpotential for injection molding tooling fabri-cation with, multi-material structures, fiber-reinforced composites, smart structures, andothers (R J Friel and R A Harris, xxxx).

Figure 12: Ultrasonic Consolidation Method

Static force due to sonotrode

Ultrasonic Vibrations

Static force by anvil

Sonotrode

Work material

Anvil

Weld zone

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APPLICATIONS

Rapid Prototyping has numerous applicationswith large variety. We have tried to classifythem according to the techniques used asfollows:

Stereolithography

Because of high surface finish and accuracy,this technique is used in making patterns forinvestment casting, RTV moulding andurethane. IBM has produced operatingdisplay units of ThinkPad tablet usingstereolithography. It is also used in fabricationof small detailed parts and production ofspecialized manufacturing tools. Marketprototypes especially used for presentationin trade shows are made using this method.

Selective Layer Sintering

This too can be used for producing patternof investment casting. Also, durable parts,large parts like air ducts can be made. Sincethe accuracy is slightly less, so less detailedparts for form and fit testing and parts withliving hinges are made using this technique.

3D Printing

Consumer goods, concept models, colourmodels for engineering related application,Turbines parts, castings and landscapemodels can be prepared..

Fused Deposition Modelling

This again produces specialized manufac-turing tools, plastics with high temperatureresistance, patterns for investment castings,parts for food-contacting application, smalldetailed parts.

Laminated Object Manufacturing

Used in making larger patterns for sandcasting, RTV modeling, parts with less details

for testing. Even in automobiles the deckparts are prepared from casting dies, thesedies are made by LOM.

Solid Ground Curing

This can produce parts with more complexdetails than that produced by SLA. Form-fitassembly test, complicated patterns forinvestment casting, medical application, softtooling.

Laser Engineered Net Shaping

Fabrication of aerospace equipments oftitanium and other metals, repair and makingof injection molding tools.


Since titanium is the most widely usedmaterial with this technology hence it makesthis method available for various medical andaerospace components(turbine blades andpump impellers).It is used to producereplacements for the hip joint and variousother implants. It is also widely used to makethe turbo charger wheel for automobiles.

Shape Deposition Modelling

It can be used to create simple assembliesin a single operation. This can be used tocreate integrated assemblies where discreteassembly is difficult. Functionally readyprototypes like the components of theautomobile, i.e. the engine components aremade from it. Also injection moulds areprepared.

Ultrasonic Additive Manufacturing

The complicated 3D components can befabricated from metal foils. Here aluminiumis the most widely used material hence thisprocess finds wide application in aerospaceand tooling application. Also used for High

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Temperature Superconductivity (HTS) appli-cation, magnetically levitated trains, forfiltering the phone call signals and routingthem, in embedded sensors and electronics.

Selective Laser Melting

Typical application include manufacturing ofspecialized complex materials, testing ofquality prototypes and manufacturing ofcomplex organic geometry.

Inkjet Printing

The application range from accurate patternsfor casting to art, jewellery and form-fit testing.

Paper Lamination Technology

It has too many applications. From modeling,silicon mould application, sand and vacuum

casting to prototypes , Industrial models, testmodels etc.

Jetted Photopolymer or PhotopolymerPhase Change Inkjet

Form fit testing, rapid tooling patterns, verydetailed parts like jewellery and fine items.

Desktop Milling

Functional prototypes, moulds and models,injection moulds and jigs.

Ballistic Particle Manufacturing

Mainly used for concept visualization. Theparts produced cannot be used for functioningdue to weak material, useful in designprocess.

GENERAL APPLICATIONS

Figure 13: Percentage Use of Rapid Prototyping Worldwide as of Year 2000, Data Basedon D.T. Pham, S.S. Dimov, Rapid Manufacturing Verlag 2001, ISBN1-85233-360-X, Page 6

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Aerospace Industry

Various components of the satellite are madeby laser sintering, electron beam melting,ultrasonic consolidation and Laser Enginee-ring Net Shaping(LENS). British AirbusEngineers aimed to print out an entire aircraftwing (2011).

Automotive Industry

Shape Deposition Modelling for productionof engine components, URBEE is to be theworld’s first 3D printed car. The deck parts ofautomobile are produced by LaminatedObject Manufacturing. Electron Beam Meltingis used to prepare turbocharger wheel ofdiesel engines.

Machinery Industry (Tooling)

It has a major market in direct part manufac-turing. Currently methods like EBM, LENS,UC, SLS, SLM and DMLS are being used,Stereolithography, Selective Layer Sintering,Fused Deposition Modelling and SolidGround Curing are used for producingpatterns for investment castings. PaperLamination Technology has vast applicationhere as stated. LENS is used for makinginjection molding tools.

Medical Industry

Implants, improve tissues with 3D printedvascular network made from sugar, even 3Dprinted human jaws for implants.

Manufacturing Industry

Sales and marketing of consumer basedproducts like shoes, clothes, other footwear,titanium necklace and other jewellery isprepared directly from direct laser sinteringand jetted photopolymer.

RP PROCESSES UNDER DEVELOPMENT

Liquid Thermal Polymerization

In this process the resin is thermosetting andit utilizes an infrared laser to create voxels.This is similar to Stereo lithography. Heatdissipation causes shrinkage and unwanteddistortion in the part; also it affects the sizeof the voxels. However, these are controllableand far better than SL. This technique is stilla part of research and development.

Liquid Metal Jet Printing

It is a freeform solid manufacturing process.Here the molten jet is printed by controlling itto specific location. The process is similar toinkjet printing unlike spray forming. Thediameter of molten sphere ranges from 100to 1000 microns, and can be changes bychanging the orifice size.

Currently research on developing of analuminium printing of mechanical parts inbeing carried out.Earlier research workincludes jetting copper, metal ball generationand solder mask for circuits.

Robo Casting and WireFeed

A new variant of the existing technique i.eLENS using material in the form of wireknown as Wire Feed process is beingdeveloped, similar is another forming processusing ceramic as raw material called RoboCasting by Sandia labs.

Direct Photo Shaping Technology

This institute is developing a process similarto stereolithography which uses a DMD forexposure. The technique is known as DirectPhoto Shaping Technology developed formetals and ceramics by SRI International.

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US Army, Mobile Parts Hospital

The U.S. Army is working on developingmedical units for soldiers in the battlefield.According to the available report, this is a 20foot portable container with facilities on spotto scan a broken bone and develop a newone using LENS, a Rapid PrototypingTechnology.

Advanced Ceramics Research, Inc.

Tucson, AZ

It has developed a high pressure fuseddeposition system, which is can be used withnumerous engineering polymers likepolycarbonate (Lexan ), polyaryletherketone(PEEK), polymethylmethacrylate (PMMA),and thermoplastic polyurethane (Pellethane)

Other Success Story

A Rapid Prototyping system which uses solidfeedstock, extruding components using solidpowders/fibres in the form of fillers to thefeedstock. This process is known asExtrusion Freeform Fabrication.

The U.S. Government is also funding thedevelopment of functional polymer matrixcomponents.

CONCLUDING REMARKS

First steps into the rapid prototypingtechnology initiated in 1988, based on firstSLA technique [28]. In leading countriesautomotive and airplane industry differentapplications were realized. A lot of specializedservice offices are acting successfully.

From the above literature review, it is clearthat there are a numerous areas such asprocess selection, material selection, layoutplanning, volume modeling, simulation which

require advanced and newer approachesdespite the current technological advance-ments in the field of RP. It is also clear thatare several research issues which need tobe addressed in RP especially in layoutplanning and part deposition planning.

Despite this progress many challenges stilllie ahead. First, efficient data flow and datahandling of 3D objects need attention.Second, optimization accuracy by bettertechnical solutions for calculating/avoidingshrinkage, distortion curing, post curing andpost curing distortion, geometric slabdistortion, creep, etc. Third, material behaviorimprovement. Fourth , mastering newprocesses meeting specific manufacturingindustry demands.

However barring these developmentalissues, the contribution of RP to themanufacturing sector has been tremendous.The applicability of these processes can befurther improved. This can possibly be doneby: First, systematically evaluating the criticalinfluencing parameters. Second , byefficiently and effectively combining thesetechnologies with conventionalmanufacturing methods. Third, extensiveinvestigation of new and innovative domains.

In addition, a probable solution to theaforementioned discussion would be to findoptimal strategies for obtaining good partdeposition of the parts in the machine volumeby improving part accuracy, improvingsurface quality, reducing the build time,reducing amount of support structures andcost subject to RP process constraints, , goodpacking by minimizing build time andrequirement of support structure volume,maximize machine volume utilization and

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produce high quality plate subject to RPprocess constraints; formulating some basicbuild rules to aid designers in order to improvethe strength of the parts made on the RPmachine by controlling parameters like: Beadwidth, Air gap, Model build temperature,Raster orientation, color, etc. subject to RPprocess constraint; developing betterframeworks for designing and manufacturingfunctionally gradient products; develop aframework to reduce anisotropy in theproducts manufactured by fused depositionmodelling technique at the design stage itselfsubject to RP process constraint.

Obtaining optimal strategies to theaforementioned areas would go a long wayin leaping forward to rapid manufacturing andbringing rapid prototyping and rapidmanufacturing at par with the conventionalmanufacturing process techniques.

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