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RAPIDPROTOTYPING
COMPUTER AIDED MANUFACTURING
ASSIGNMENT
Presented by
S.SAMPATH KUMAR.
M.Tech Ist year.
(Product design and manufacturing)
Pondicherry engineering college.
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CONDENT
1.
Definition of Rapid Prototyping.2. Why is Rapid Prototyping Important?
3. Classification of Rapid Prototyping
Technologies.4. Advantages of Rapid Prototyping.
5. Disadvantages of Rapid Prototyping.
6. Applications and Benefits of RapidPrototyping.
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INTRODUCTION OFRAPIDPROTOTYPING
Rapid prototype is a process wherein a
working model or prototype is developed
for the purpose of testing the variousproduct features like design, ideas,
features, functionality, performance and
output. This process of development of
working model is quite quick. The user
can ive an earl feedback re ardin theO C O O
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INTRODUCTION OF
RAPIDPROTOTYPING cont...The Rapid prototype that is
developed by the process of rapid
prototyping is based on the
performance of earlier designs. Hence,it is possible to correct the defects or
problems in the design by taking
corrective measures. The product can
be produced if the prototype meets the
re uirements of all desi nin ob ectives
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Definition of RapidPrototyping (RP)
A family of fabrication processesdeveloped to make engineeringprototypes in minimum lead time
based on a CAD model of the item
Traditional method is machining
Can require significant lead-times several
weeks, depending on part complexity anddifficulty in ordering materials
RP allows a part to be made in hours
or days, given that a computer
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Why is Rapid PrototypingImportant?
Product designers want to have aphysical model of a new part orproduct design rather than just a
computer model or line drawing Creating a prototype is an integral step in
design
A virtual prototype (a CAD model of the part)may not be sufficient for the designer tovisualize the part adequately
Using RP to make the prototype, the designer
can see and feel the part and assess its meritsand shortcomin s
l ifi i f
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Classification of RPTechnologies
There are various ways to classify theRP techniques that have currentlybeen developed
The RP classification used here isbased on the form of the startingmaterial:
1. Liquid-based
a) Stereolithography
2. Solid-based
a) Fused Deposition Modeling (FDM)
b) Laminated Object Manufacturing (LOM)
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Figure 34.2 Stereolithography: (1) at the start of the process, in which theinitial layer is added to the platform; and (2) after several layers have beenadded so that the part geometry gradually takes form.
Stereolithography
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Stereolithography (STL)RP process for fabricating a solid plasticpart out of a photosensitive liquidpolymer using a directed laser beam tosolidify the polymer
Part fabrication is accomplished as aseries of layers - each layer is addedonto the previous layer to gradually
build the 3-D geometry The first addition RP technology -
introduced 1988 by 3D Systems Inc.
based on the work of Charles Hull
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Figure 34.3 A part produced by stereolithography(photo courtesy of 3D Systems, Inc.).
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SLA Video http://www.acucast.com/video.htm
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F d D iti M d li
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Fused Deposition Modeling(FDM)
RP process in which a long filament ofwax or polymer is extruded onto existingpart surface from a workhead tocomplete each new layer
Workhead is controlled in thex-yplaneduring each layer and then moves upby a distance equal to one layer in the
z-direction Extrudate is solidified and cold welded
to the cooler part surface in about 0.1
s
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Stratasys, Eden Prarie, MN
patent 1992
robotically guided fiber extrusion
accuracy 0.005
casting and machinable waxes,
polyolefin, ABS water soluble or wax supports
Fused Deposition Modeling
FDM
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FDM material
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Figure 34.5 Laminated object manufacturing.
Laminated Object Manufacturing
L i t d Obj t
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Laminated ObjectManufacturing (LOM)
Solid physical model made by stackinglayers of sheet stock, each an outline ofthe cross-sectional shape of a CAD modelthat is sliced into layers
Starting sheet stock includes paper,plastic, cellulose, metals, or fiber-reinforced materials
The sheet is usually supplied withadhesive backing as rolls that arespooled between two reels
After cutting, excess material in thelayer remains in place to support the
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Logon the website :
www.xpress3d.com
www.acucast.com
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ADVANTAGES
High quality product is easilydelivered by way of Rapidprototyping.
Rapid prototyping enablesdevelopment time and costs.
There are many innovative ways inwhich Rapid prototyping can be used.
As the development costs arereduced, Rapid prototyping proves tobe cost effective.
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DISADVANTAGES
One more disadvantage of rapid
prototyping is that it may not besuitable for large sized applications.
The user may have very high
expectations about the prototypesperformance and the designer isunable to deliver these.
The producer may produce aninadequate system that is unable tomeet the overall demands of the
organization.
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RP Applications
Applications of rapid prototyping canbe classified into three categories:
1. Design
2. Engineering analysis and planning
3. Tooling and manufacturing
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Design Applications
Designers are able to confirm theirdesign by building a real physicalmodel in minimum time using RP
Design benefits of RP: Reduced lead times to produce prototypes
Improved ability to visualize part geometry
Early detection of design errors Increased capability to compute mass
properties
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Engineering Analysis andPlanning
Existence of part allows certainengineering analysis and planningactivities to be accomplished that
would be more difficult without thephysical entity
Comparison of different shapes and styles to
determine aesthetic appeal Wind tunnel testing of streamline shapes
Stress analysis of physical model
Fabrication of pre-production parts for processplanning and tool design
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Tooling Applications
Called rapid tool making (RTM) whenRP is used to fabricate productiontooling
Two approaches for tool-making:
1. Indirect RTM method
2. Direct RTM method
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