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8/3/2019 07 Rapid Pro to Typing
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Rapid Prototyping
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Rapid Prototyping
Layer by layer fabrication ofthree-dimensional physicalmodels from CAD
Fast and inexpensive alternativefor producing prototypes andfunctional models
Build parts in thin layers
Minimum operation time;typically runs unattended
Rapid Prototyping has
surgical applications
http://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.html8/3/2019 07 Rapid Pro to Typing
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Medical Modeling - Zcorp
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Rapid Prototyping Cycle
.STL (stereolithography) isstandard file format for allU.S. rapid prototypingsystems
Preprocessing prepares .STLfile for various rapidprototyping systems
Build process can last from a
few hours to several days Post processing: removal of
part from machine, supportremoval, sanding
Stereolithography (SL or SLA from Stereolithography Aparatus)
is an additive manufacturing technology for producing models,prototypes, patterns, and in some cases, production parts.
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Rapid Prototyping Process (Damvig)
A computer-controlled laser beam is
scanned across the surface of a vat of
liquid photopolymer, instantly
solidifying the liquid at each point of
contact. Using data generated from aCAD file, individual cross-sections of
the three-dimensional geometry are
solidified in turn to build up a solid
part layer by layer. In this way evenhighly complex geometries can be
built in a few hours without requiring
any tools.
http://www.damvig.com/english/index.htmhttp://www.damvig.com/english/index.htm8/3/2019 07 Rapid Pro to Typing
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Rapid Prototyping (RP)
Introduction of RP Generate a prototyping by Laying Manufacturing
Technology - composite material layer by layer
Build in one step - directly from model to
manufacturing
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Rapid Prototyping (RP)
Development of RP First Phase : Manual (or Hard) Prototyping
Age-old practice for many centuries
Prototyping as a skilled craft is traditional and manual
and based on material of prototype
Natural prototyping technique
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Rapid Prototyping (RP)
Development of RP Second Phase : Soft (or Virtual) Prototyping
Mid 1970s
Increasing complexity
Can be stressed, simulated and tested with exact
mechanical and other properties
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Rapid Prototyping (RP)
Development of RP Third Phase : Rapid Prototyping
Mid 1980s
Hard prototype made in a very short turnaround time
(relies on CAD modelling)
Prototype can be used for limited testing
prototype can consist in the manufacturing of the
products
3 times complex as soft prototyping
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Rapid Prototyping (RP)
Fundamentals of RP Building computer model
Model is building by CAD/CAM system
Model must be defined as enclosed volume or solid
Converting model into STL file format
STereoLithography (STL) file is a standard format to
describe CAD geometry used in RP system
STL file file approximates the surfaces of the modelby polygons
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Rapid Prototyping (RP)
Fundamentals of RP Fabricating the model
Building model layer by layer
Forming a 3D model by solidification of
liquid/powder
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Rapid Prototyping (RP)
Applications of RP For design evaluation
Touch and holding a physical prototype
For function verification
e.g. assembly, kinematics performance, and
aerodynamic performance
Models for further manufacturing processes
e.g. Vacuum casting, spray metal moulding,investment casting, etc.
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Rapid Prototyping (RP)
Advantages and DisadvantagesNo planning of process sequences
No specific equipment for handling materials
No transportation between machiningFeatures-based design and feature recognition
are unnecessary
Defining a blank geometry is unnecessary
Defining different setups or complex sequences
of handling material is unnecessary
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Rapid Prototyping (RP)
Advantages and DisadvantagesNo need to consider jigs and fixtures
Designing and manufacturing moulds and dies
Specific materials are restricted
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Rapid Prototyping (RP)
Role of RP in Product Development Cycle Product design
Increase part complexity and diversity with little
effect on lead time and cost
Minimise time-consuming discussion and evaluationsof manufacturing possibilities
Tool design and manufacturing
Minimise design, manufacturing and verification of
tooling
Reduce parts count and eliminate tool wear
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Rapid Prototyping (RP)
Role of RP in Product Development Cycle Assembly and test
Reduce labour content of manufacturing (e.g.
machining, casting, inspection and assembly, etc.)
Reduce material costs (e.g. handling, waste,transportation, spare and inventory, etc.)
Function testing
Avoid design misinterpretations, i.e. what you design
is what get)
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Rapid Prototyping (RP)
Due to the newness of the technology, thereare already so many words for RP used today:
RP( most commonly used) - Rapid Prototyping
RPTM(inc. new development trends) - Rapid
Prototyping, Tooling and Manufacture
Direct CAD Manufacturing/Desktop
Manufacturing/Instant Manufacturing/CAD
Oriented Manufacturing = RP