THE TECHNICAL PAPER PRESENTATION ON Rapid prototyping

Submitted by

Mr. VILAS P. KSHIRSAGAR Mr. TUSHAR V. KULKARNI Mr. SANTOSH D. SOLANKE Mr. SUNIL U. DHAKANE Mr. SANJAY P. HINGANKAR

Under the guidance of

PROF. C.V. DESHMUKH

( H.O.D.)

PROF. S.K. PATIL

PROF. D.V. SHIRBHATE

Presentation at :

Govt. College of Engg., algaon. !"""#!""$

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ACKNOWLEDGEMENT
It gi es !e great p"eas#re on $ringing o#t t%e se!inar entit"ed&

%&'(D '%O)O)*'(+G
I 'is% to e(press !y %eart $o#nd t%an)s to !y g#ide Prof. C.V. Deshmukh
(H.O.D.),

Prof. D.V.

Shirbhate & Prof. S.K. Patil *or t%eir g#idan+e& en+o#rage!ent and a""o'ing to s#++eeding t%e pro,e+tLast& not t%e "east----& !y +ordia" t%an)s to a"" t%ose *riends and 'e"" 'is%ers& '%o +ontri$#ted t%eir $it in t%e s#++ess*#" +o!p"etion o* !y tas)-

Mr. VILAS P. KSHIRSAGAR

III Year B.E. Prod. College of Engg. & Tech. ,Akola

Rapid Prototyping

INDE.
Sr.No.
1.

Particu ar
Introduction 1 What is Prototyping Rapid prototyping differs by

Pa!" No.

2. 3. . 5. 6.

The principle Advantages Need for Prototype !evelop"ent #ase $tudy for Rapid Prototyping %asic Process $tereolithography '() 3! Plotting

2 2 3 3 &

7. 8. 9.

)aterials for Rapid Prototyping #onclusion %ibliography

12 13 1

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An Introd#+tion to Rapid Prototyping

The ability to rapidly produce accurate, tangible models of products designed on a computer aided design system. Rapid prototyping is a technology of producing a, 3 dimensional visual prototype or model direct from a CAD file. Rapid prototyping is based on CAD computer aided design.

#$at i% Ra&i' Protot(&i)!*

The term "rapid prototyping" is a relatively new e pression for the generation of three!dimensional models manufactured without the need for machining or tooling. "roduction of models by machining has a number of limitations#! $. %aterial removed during forming is difficult to reclaim. &. %achining, in the form of drilling, turning, milling, spar' erosion etc., is limited by the shapes it can produce. 3. (n the event of design change conventional tooling such as patterns, core bo es, dies, )igs etc., become e pensive to alter and, in many cases, may re*uire complete re!manufacture.

Ra&i' &rotot(&i)! 'i++"r% ,(-.

Adding material layer by layer until the desired shape is achieved, immediately reducing or avoiding the loss of material. Cutting out

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the conventional draftsperson, patternma'er and in some situations even the moulder, the system goes a long way towards reducing time ta'en and cost and improving accuracy.

T$" &ri)ci& " a'/a)ta!"% o+ u%i)! t$i% t"c$)o o!( ar"- .

$. +peed at which the solid model is generated. &. The comple ity of the model does not form any limitations to its production. 3. The early use of these models was to assist the designer in determining fit and form. (t also provided the sales team with a 3 dimensional ob)ect to show to a prospective customer, this being far better than the traditional orthographic drawing which many people find difficult to interpret. ,. Concept modeling -. Aesthetic .. To ma'e an impossible ob)ect.

T$" N""' +or a Protot(&"

(t is very difficult, and in many instances impossible, to produce an article that will serve the purpose of use without ma'ing modifications to the original shape or general design. There are many e amples of design failure that have been the cause of serious in)ury and costly litigation. Rapid "rototyping concentrates the mind on getting the product Right /irst Time

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Ot$"r u%"% +or RP 0o'" % ar"-.

Discussion piece. Design and fit. Assembly capabilities. +uitability of mechanical properties. %anufacturing process capabilities 0forging, casting, pressing, fabrication etc.1

D"/" o&0")t
The first rapid prototyping system was developed on to the 2+ model in $344 and gave the 5ngg. the opportunity to produce 3 dimensional ob)ect from computer aided design 0CAD1 data. The development of this technology has reach into many of traditional fields.

T$" Ca%" +or Ra&i' Protot(&i)!

The prime concern of any management is to maintain and, where possible, improve profitability. 6e are all aware that profits accrue when income from sales e ceed total cost and that profits can be increased by improved sales or reduction in costs, or both. %any technologies have been developed which have been successful in reducing the labour content, which, in most cases is the ma)or cost.

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Rapid prototyping is only some ten years old and is already proving to be a very cost!effective way of producing models7patterns. There are over -88 +9A machines installed world wide 0appro imately &8 in the 2:1 to famous companies such as #! /ord, ;eneral %otors, Rover, Rolls Royce, (<%, <oeing, <Ae. These companies have recognised the power of this technology to boost their profits and competitiveness. 6hilst most companies are, understandably, reluctant to reveal the e tent to which the technology contributes to their profitability, <Ae. claims that one of its systems paid for itself within - months. Rover, who bought the largest system available, is already considering the purchase of other system. =f the -88 systems sold world!wide, about $-> are being used by R" bureau , operating on a sub!contract basis. (n the 2: this number is significantly higher at -8>. All the companies are e ploiting the power of R" to increase their profits as discussed below. Increasing $ales by*+

* * * * * *

"roducing visual models for mar'et research, publicity, pac'aging etc., ;etting to mar'et sooner. ;enerating customer goodwill through improved *uality. 5 panding the product range. Reducing the cost and fear of failure. ?isual %odels

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Consumer product manufacturers find value in having tangible models of their proposed products to show to customers. (<% used +9A to produce operating display units of its Thin'"ad tablet computer for the annual C=%D5@ show. :ey Tronics, who manufacture computer 'eyboards, create physical parts for customer approval. 9ogitech, the worlds largest manufacturer of pointing devices, was as'ed, by a "blue chip computer company" to *uote on a uni*ue two!button mouseA in less than two wee's from the initial re*uest 9ogitechBs team returned with a functional +9A prototype. The customerBs reaction was one of Cdisbelief D. "art *uality was so superior that the computer giant awarded the contract on the spot. (t is thought that this single order paid for the +9A system. Coca!Cola used R" to design the nostalgic 0co'e bottle1 curves into a contemporary &8 ounce plastic Co'e bottle.

G"tti)! to Mar1"t Soo)"r

The phrase "Time to %ar'et" is first thought to have been used in a classic $343 article by %c:insey E Co on product development that stated# "+i months of delay can reduce a productBs life cycle profits by 33>". The author of that article has since written# "The first product to mar'et has a $88> share of that mar'et in the beginning. The earlier a product appears, the

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better are its prospects for obtaining and retaining a large share of the mar'etF /or each month cut from a productBs development cycle a month can be added to its sales life, representing an e tra month of revenue and profitF (t gains more customer loyalty due to the cost of switching to another productF A third benefit is higher profit margins. (f a new product appears before there is competition, the company will en)oy more pricing freedom, ma'ing higher profit marginsF" De"uy, the surgical implant manufacturers, state# The ma)or goals are decreasing the time to develop a product, while allowing manufacturing to launch the product *uic'ly, resulting in a larger return on investmentF The return from launching a single product several months early pays for the entire technology investment."

G")"rati)! Cu%to0"r Goo'2i t$rou!$ I0&ro/"' 3ua it(

The end result has been less re!design, improved products and most importantly, greater customer satisfaction. This has lead to many companies in the 2+A producing a R" model with every *uote.

E4&a)'i)! Pro'uct Ra)!"

TodayBs mar'et place is characterised by more fre*uent introductions of more product variants each having a life cycle than the previous one. (n addition, lead!times demanded are shorter than ever before.

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Clearly, R" ma'es a positive contribution here, by compressing development times, thus ma'ing it possible to respond to the demands of the niche mar'ets and to introduce new products more fre*uently.

R"'uci)! t$" Co%t a)' F"ar o+ Fai ur"

(t ta'es a very confident person to allocate 7 sanction large amounts of money and resources on tooling for a product that might not ma'e it on the mar'et. This will inevitably ma'e people cautious and restrict their design flair to those tried and tested shapes and systems. 6here a relatively cheap model can be produced *uic'ly it reduces the fear that traditional methods attract allowing the designer to be more adventurous.

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Rapid Prototyping& t%e $asi+ pro+ess

R" machines process CAD data by slicing the computer model into layers, each layer being typically 8.$ ! 8.&-mm thic'. The machine then uses this data to construct the model layer by layer, each layer being bonded to the previous until a solid ob)ect is formed. Due to this laminated method of construction a stepped surface is developed on curved faces, the removal of which is essential if ma imum advantage of the process is to be realised The models are built in a build envelope or tan', and so do not have mould cavity walls or patterns to rest on during construction. As a result a support structure is also built along with the model itself. =nce the model is complete, and the remaining powder or li*uid in the build tan' is e punged, and the support structure must be removed. This is similar to the removal of risers and channels in traditional casting processes. %ost models can then be sub)ected to post production methods 0e.g. sanding1. The lamination and the support structure is designed by the software used to drive the process. This translates a conventional 3D CAD drawing into the +T9 format used by the Rapid "rototyping machines 0see +oftware1

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T(&"%
There are three ma)or types of Rapid "rototyping. They are $. "hotopolymer 0+tereolithography1,

2. 9aminated ob)ect modeling,

3. 3D "lotting. As Rapid "rototyping technology develops, the number of methods which can be used to produce prototypes increase, these are some of them.

5. Ra&i' Protot(&i)! . Fu%"' D"&o%itio) Ma)u+actur" 6FDM7

%aterials used include#! A<+ %edical A<+ (nvestment casting wa 5lastomers similar to low and high density "olyethylene "olypropylene. A thermo!polymer is e truded from a travelling head having a single, fine noGGle. The head travels in the @ a is while the table or platform travels in the H a is and descends at predetermined increments in the I a is. =n leaving the noGGle the thermo! polymer adheres and hardens to the previous layer.

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8. Ra&i' Protot(&i)! . La0i)at"' O,9"ct Ma)u+acturi)! 6LOM7

9=% was developed by %ichael /eygin of Jelysis. As the name implies the process laminates thin sheets of film 0paper or plastic1, the laser has only to cut7scan the periphery of each layer and not the whole surface as in +9A. The build material 0paper with a thermo!setting resin glue on its under side1 is stretched from a supply roller across an anvil or platform to a ta'e! up roller on the other side. A heated roller passes over the paper bonding it to the platform or previous layer. A laser, focused to penetrate through one thic'ness of paper cuts the profile of that layer. The e cess paper around and inside the model is etched into small s*uares to facilitate its removal. %eanwhile, this surplus material provides support for the developing model during the build process. The process of gluing and cutting continuous layer by layer until the model is complete. To reduce the build time, double or even triple layers are cut at one time which increases the siGe of the steps on curved surfaces and the post processing necessary to smooth those surfaces.

Applications of '() ob,ects*

9=% ob)ects are durable, multilayered structures which can be machined, sanded, polished, coated and painted. 2sed as precise patterns for secondary tooling processes such as rubber moulding, sand casting and direct investment casting.

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2sed for limited testing. 2sed as visual models. KA+A have used the 9=% to produce $& CJotB gas manifold for the shuttle main engine.

:. SLA Proc"%%. 6 St"r"o it$o!ra&$( 7

+9A system builds shapes using light to selectively solidify li*uid photocurable resins.

Principle *
9aser +9A crates acrylic or epo y parts directly from a vat of li*uid photocurable polymer by selectively solidifying the polymer with a scanning laser beam. <uilding !up Techni*ue $. <uilding ! up parts on an elevator platform. &. The platform is lowered into the vat by the distance of the layer thic'ness. 3. ;uiding a laser beam using servo!controlled galvanometer mirror and drawing a cross !sectional layer in the !y plane to form a solid section. ,. The platform is then lowered into the vat and the ne t layer is drawn and adhered to the previous layer. -. These steps are repeated, layer!by!layer until the complete part is built up.

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Materia"s *or R-PThere is a clear need to improve the mechanical properties of the stereolithography resins and plastics currently being used. 6a !li'e material that can be used for investment casting of metal parts. "olystyrene for selective laser sintering. "olyamide 0nylon1 is generally used for parts re*uiring higher strength and7 or toughness. A<+ that is, with ductility to test snap fit, fle ible hinges and other functional properties of a design.

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Con+"#sion
TodayBs mar'et is customer mar'et. R E D is the heart of any progressing, developing industry because RED can only word of new blood in industry, so that no obsolance stage will covered in the life of industry. R E D 5ngg. developing new shapes, siGe, design, type of various component for the establishing machine or product but hurdle is to produce the part according to design immediately for getting immediate solution to the problem which they want to rid off. Kow the time has come where, the design egg. Lust can imagine the new design, reproduce on the paper and within the few minute the product will be ready with this technology 0 prototyping1 because the time has come where this technology is capable to give the product manufactured within few minutes if product details are fed to computer as data.

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/i$"iograp%y
$. M R.". +ystemsN %ech. 5ngg., April. $33$, "" 3,!,3

&. Lacobs. "aul /. M R.". E %anufacturingN , +ociety of manufacturing 5ngg., Dearborn $33&.

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x $ea! #o%%le y

Plat form

Process Chamber

Fig.

F se! !e"ositio#

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'ca##er &aser

&aser si#(i#g

)le*atio# ' ""ort ' rface of resi# Platform ,at +esi#

St"r"o it$o!ra&$(

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Cro%% $atc$i)! ,( a%"r

&ami#ate! -b.ect /a# fact ri#g 0&-/1

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