Application of CAD in Rapid Prototyping Technology

Mr.Sanjay C. Kumawat
Lecturer in mechanical Department,
J.T.M.College Of Engg.Faizpur, Jalgaon
2

Mrs. A.L.Gawali
Lecturer in Mechanical. Department.
SSGBCOE&T Bhusawal (MH)
E-mail [email protected]

Abstract
Now a day, one of the critical factors in competitive technology is time to market along
with foolproof design. This critical factor indicates the entire product design cycle from concept
to product design to prototype to manufacturing process design to actual implementation. To
have command over this critical factor Computer aided designing (CAD) and manufacturing
(CAM) is taking hold as a mean of speeding the time to market for new product development.
This paper described how CAD approach is used in Rapid Prototyping techniques (RPT) for
design and development of new products. Use of this CAD techniques in RPT techniques shorten
the time to market and further for research and development of time of new products.
Keywords: CAD/CAM, Rapid Prototyping Technology (RPT)
1.0 Introduction
Computer-Aided-Design (CAD) involves the use of computers to create product design
drawing and 3D models. This CAD is associated with interactive computer graphics. CAD
system is powerful tool and used in mechanical design, and geometrical modeling of products
and components.
Computer-Aided-Manufacturing (CAM) involves the use of computer technology to
assist in all the phases of manufacturing a product, including process and production planning,
machining, scheduling, management, and quality control. These two-system i.e. CAD/CAM are
combined to get added benefit. The database developed during CAD is stored and then CAM
processes it further, into the necessary data and instructions for product quality [2].
Rapid Prototyping Technology (RPT) is developed in 1988. RP enable the development
of a geometrically exact replica of a part in matter of hours, as compare to days or weeks using
traditional model-shop techniques. Rapid prototyping of physical parts also known as solid free
from fabrication, desktop manufacturing or layer manufacturing technology [1].
2.0 Prototyping Definition
A prototyping is the first or original example of something that has been or will be copied or
developed; it is a model or preliminary version [4]. There are three phases of prototyping as
described follows.

2.1 First Phase: Manual (or hard) prototyping

The first phase began many centuries ago. In this phase, prototypes are typically not very
sophisticated and fabrication of prototype takes on average about four weeks. The techniques
used in making these prototypes tend to be craft-based and extremely labour intensive [4].
2.2 Second Phase: Soft or Virtual prototyping.
In this phase, computer models were created using CAD modeling software and can be tested,
stressed, analyzed and modified just considering like physical prototype [4].
2.3 Third Phase: Rapid Prototyping
Rapid Prototyping of physical parts, also known as, desktop manufacturing, free-form
fabrication, or layer manufacturing technology represents the third phase in the evolution of
prototyping [4].
3.0. Introduction to Rapid Prototyping
Rapid Prototyping is an important recent advancement in manufacturing. The Rapid
Prototyping is a process by which a solid physical model of a part is made directly form a 3dimensional CAD drawing. The term rapid prototyping (RP) also refers to a class of technologies
that can automatically construct physical models from Computer-Aided Design (CAD) data. This
technique was developed in mid-1980s [8].
Rapid prototyping is an "additive" process, combining layers of paper, wax, or plastic to
create a solid object. In contrast, most machining processes (milling, drilling, grinding, etc.) are
"subtractive" processes that remove material from a solid block. RPs additive nature allows it to
create objects with complicated internal features that cannot be manufactured by other means.
These "three dimensional printers" allow designers to quickly create tangible prototypes
of their designs, rather than just two-dimensional pictures. Such models have numerous uses.
They make excellent visual aids for communicating ideas with co-workers or customers. In
addition, prototypes can be used for design testing. For example, an aerospace engineer might
mount a model airfoil in a wind tunnel to measure lift and drag forces [4].
Of course, "rapid" is a relative term. Most prototypes require from three to seventy-two
hours to build, depending on the size and complexity of the object. This may seem slow, but it is

much faster than the weeks or months required to make a prototype by traditional means such as
machining. These dramatic time savings allow manufacturers to bring products to market faster
and more cheaply. At least six different rapid prototyping techniques are commercially available,
each with unique strengths [7].

Fig. 1 CAD Approach for Rapid Prototyping Fig .2 The basic procedure for RP modeling
4.0 Benefits of Rapid Prototype Technique [RPT].

Helps in complete visualization of the physical model.

Communicating desired form, fit, and function.

Providing feedback about ergonomic and aesthetic requirements.

Providing an example to a vendor for quotation.

Facilitating quick changes in a design (especially true for castings).

Reduced cycle times and increased innovation.

we can build mold components directly from the CAD geometry

5.0 Applications of Rapid Prototype Technique.

In design verification

Dental device development.

In product development.

Biomedical Industry.

In engineering Analysis

Jewelry Industry.

In Manufacturing Tooling.

Coin Industry.

Aerospace Industry.

Tableware Industry.

Automotive Industry.

Electronic products.

6.0 Limitations of Rapid Prototype Technique.

Limitation on maximum size of the model. Large parts usually must be built separately and
connected manually.
Larger parts can be quite expensive.
Limited material properties.
Varying accuracy between the x-, y-planes and the z-plane.
Because parts are built in sections, the properties may not be very isotropic.
Initial investment and maintenance cost is high.
7.0 .STL file as a prototype data
3D Systems developed the STL file format to transfer geometry to the SLA machine. STL
files are faceted representations of data composed of triangles. The data for the STL file can come
from a variety of sources: a solid CAD model, a sewn (air-tight) surface quilt, MRI (magnetic
resonance imaging) and x-ray data, and laser and digitizing arm scans.
Representation methods used to describe CAD geometry vary from one system to another.
A standard interface is needed to convey geometric descriptions from various CAD packages to
RP systems. The STL (StereoLithography) file i.e. (. STL file) consists of an unordered list of
triangular facets representing the outside skin of an object. There are two STL file formats. One is
the ASCII format and the other is binary format. The size of an ASCII STL file is lager than that
of the binary format but is human readable [2].
In an STL file, triangular facets are described by a set of X, Y, and Z co-ordinates for each
of the three vertices and a unit normal vector with x, y, and z to indicate which side of facet is an
inside the object. An example is shown in Fig. 3.
There are several advantages with the STL file. Firstly, it
provides a simple method of representing 3-dimensional CAD
data. Secondly, it is a de facto standard, which is used in most of
the CAD systems and RP systems. Finally, it can provide simple
files for data transfer for geometric shapes [3].
Several disadvantage of the STL file exist. Firstly, the
STL file is many times larger than the original CAD data file for

a given accuracy parameter. The STL file carries much redundant

information such as

duplicate vertices and edges.

Fig. 3 .STL file with triangular facets.
8.0 The Basic Process for all Rapid Prototype Technique.
Although several rapid prototyping techniques exist, all employ the same basic five-step
process. The steps are as described follows.
1) Create a CAD model of the design.
2) Convert the CAD model to STL format.
3) Slice the STL file into thin cross-sectional layers.
4) Construct the model one layer atop another.
5) Clean and finish the model.
First step, the object to be built is modeled using a Computer-Aided Design (CAD)
software package. Solid modelers, such as Pro/ENGINEER, Solid Works, Inventor, and Catia
tend to represent 3-D objects more accurately than wire-frame modelers such as AutoCAD, and
will therefore yield better results. The various CAD packages use a number of different
algorithms to represent solid objects. To establish consistency, the STL (Stereolithography, the
first RP technique) format has been adopted as the standard of the rapid prototyping industry.
The second step, therefore, is to convert the CAD file into STL format. This format
represents a 3D surface as an assembly of planar triangles, "like the facets of a cut jewel." The file
contains the coordinates of the vertices and the direction of the outward normal of each triangle.
Because STL files use planar elements, they cannot represent curved surfaces exactly. Increasing
the number of triangles improves the approximation, but at the cost of bigger file size. Large,
complicated files require more time to pre-process and build, so the designer must balance
accuracy with manageability to produce a useful STL file.
In the third step, a pre-processing program prepares the STL file to be built. Several
programs are available, and most allow the user to adjust the size, location and orientation of the
model. Build orientation is important for several reasons. First, properties of rapid prototypes vary
from one coordinate direction to another. For example, prototypes are usually weaker and less
accurate in the z (vertical) direction than in the x-y plane. In addition, part orientation partially

determines the amount of time required to build the model. Placing the shortest dimension in the z
direction reduces the number of layers, thereby shortening build time. The preprocessing software
slices the STL model into a number of layers from 0.01 mm to 0.7 mm thick, depending on the
build technique. The program may also generate an auxiliary structure to support the model
during the build. Supports are useful for delicate features such as overhangs, internal cavities, and
thin-walled sections.
The fourth step is the actual construction of the part. Using one of several techniques as
described above. RP machines build one layer at a time from polymers, paper, or powdered metal.
Most machines are fairly autonomous, needing little human intervention.
The final step is post-processing. This involves removing the prototype from the machine
and detaching any supports. Some photosensitive materials need to be fully cured before use.
Prototypes may also require minor cleaning and surface treatment. Sanding, sealing, and/or
painting the model will improve its appearance and durability.
9.0 Different Rapid Prototyping Techniques.
9.1 Stereolithography Technique.
Patented in 1986, Stereolithography started the rapid prototyping revolution. The
technique builds three-dimensional models from liquid photosensitive polymers that solidify

Fig.1 Stereolithography Technique.

when exposed to ultraviolet light. The model is built upon a platform situated just below
the surface in a vat of liquid epoxy or acrylate resin. A low-power highly focused UV laser traces
out the first layer, solidifying the models cross section while leaving excess areas liquid. Next, an
elevator incrementally lowers the platform into the liquid polymer. A sweeper re-coats the

solidified layer with liquid, and the laser traces the second layer atop the first. This process is
repeated until the prototype is complete. Afterwards, the solid part is removed from the vat and
rinsed clean of excess liquid. Supports are broken off and the model is then placed in an
ultraviolet oven for complete curing. Stereolithography Apparatus (SLA) machines have been
made since 1988 by 3D Systems of Valencia, CA. To this day, 3D Systems is the industry leader,
selling more RP machines than any other company. Because it was the first technique,
StereoLithography is regarded as a benchmark by which other technologies are judged. Fig. 4
Shows the Stereolithography process.
9.2 Laminated Object Manufacturing Technique.
In this technique, developed by Helisys of Torrance, CA, layers of adhesive-coated sheet
material are bonded together to form a prototype. The original material consists of paper
laminated with heat-activated glue and rolled up on spools. A feeder/collector mechanism
advances the sheet over the build platform, where a base has been constructed from paper and
double-sided foam tape. Next, a heated roller applies pressure to bond the paper to the base. A
focused laser cuts the outline of the first layer into the paper and then cross-hatches the excess
area (the negative space in the prototype). Cross-hatching breaks up the extra material, making it
easier to remove during post-processing. During the build, the excess material provides excellent
support for overhangs and thin-walled sections.
After the first layer is cutting is completed, the platform lowers out of the way and fresh
material is advanced. The platform rises to slightly below the previous height, the roller bonds the
second layer to the first, and the laser cuts the second layer. This process is repeated as needed to
build the part, which will have a wood-like texture. Because the models are made of paper, they
must be sealed and finished with paint or varnish to prevent moisture damage. Fig. 5 Shows the
Laminated Object Manufacturing process.

Fig.2 Laminated Object Manufacturing Technique.

9.3 Selective Laser Sintering Technique.

Fig.3 Selective Laser Sintering Technique.

Developed by Carl Deckard for his masters thesis at the University of Texas, selective laser
sintering was patented in 1989. The technique uses a laser beam to selectively fuse powdered
materials, such as nylon, elastomer, and metal, into a solid object. Parts are built upon a platform,
which sits just below the surface in a bin of the heat-fusible powder. A laser traces the pattern of
the first layer, sintering it together. The platform is lowered by the height of the next layer and
powder is reapplied. This process continues until the part is complete. Excess powder in each
layer helps to support the part during the build.

9.4 Fused Deposition Modeling Technique.

In this technique, filaments (appx. 2.8-mm dia.) of heated thermoplastic are extruded from
a tip that moves in the x-y plane. Like a baker decorating a cake, the controlled extrusion head
deposit very thin beads of material onto the build platform to form the first layer. The platform is
maintained at a lower temperature, so that the thermoplastic quickly hardens. After the platform
lowers, the extrusion head deposits a second layer upon the first. Supports are built along the way,
fastened to the part either with a second, weaker material or with a perforated junction. Materials
include polyester, polypropylene, ABS, elastomers, & investment casting wax. Fig. 6 Shows the
Fused Deposition Modeling Technique.

Fig.4 Fused Deposition Modeling Technique.

9.5 Solid Ground Curing Technique.

Developed by Cubital, solid ground curing (SGC) is somewhat similar to Stereolithography
(SLA) in that both use ultraviolet light to selectively harden photosensitive polymers. Unlike
SLA, SGC cures an entire layer at a time. Solid ground curing, which is also known as the solider
process. First, photosensitive resin is sprayed on the build platform. Next, the machine develops a
photo mask (like a stencil) of the layer to be built. This photo mask is printed on a glass plate
above the build platform using an electrostatic process similar to that found in photocopiers. The
mask is then exposed to UV light, which only passes through the transparent portions of the mask
to selectively harden the shape of the current layer.
After the layer is cured, the machine vacuums up the excess liquid resin and sprays wax in
its place to support the model during the build. The top surface is milled flat and then the process
repeats to build the next layer. When the part is complete, it must be de-waxed by immersing it in
a solvent bath.

Figure 5 SGC steps for each layer:

1) Mask preparation,
2) Applying liquid photopolymer layer,
3) Mask positioning and exposure of layer,
4) Uncured polymer removed from surface,
5) wax filling,
6) Milling for flatness and thickness.

9.6 3-D Printing Technique.

Parts are built upon a platform situated in
a bin full of powder material. A 3-D printing
head selectively "prints" binder to fuse the
powder together in the desired areas. Unbound
powder remains to support the part. The
platform is lowered, more powder added and
leveled, and the process repeated.

Fig. 7 3-D Printing Process.

When finished, the green part is sintered and then removed from the unbound powder. 3-D
Printing used to produce ceramic molds and cores for investment casting, also to make powder
metal tools and products. After each layer, a cutting tool mills the top surface to uniform height.
This yields extremely good accuracy, allowing the machines to be used in the jewelry industry.
3D Systems has also developed a 3-D printing based system. Fig. 7 shows the 3-D Printing
process.
Conclusion
Rapid Tooling is enabling art to production of quality parts and accelerating time to market by
concentrating on tool rather than the part. For the same work a company might have taken 5-6
months to develop and implementation of a new product development previously; it is now
possible to accomplish the target in as little as 2-3 weeks. So, for achieving this time to market
fastly CAD/CAM and RPT technologies are used .This paper highlights the salient features of this
technology,
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