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Seminar report

On

Rapid Prototyping
Submitted in partial fulfillment of the requirement for the award of degree
Of Mechanical

SUBMITTED TO: SUBMITTED BY:

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Preface
I have made this report file on the topic Rapid Prototyping; I have tried my best to elucidate all
the relevant detail to the topic to be included in the report. While in the beginning I have tried to
give a general view about this topic.

My efforts and wholehearted co-corporation of each and everyone has ended on a successful
note. I express my sincere gratitude to …………..who assisting me throughout the preparation of
this topic. I thank him for providing me the reinforcement, confidence and most importantly the
track for the topic whenever I needed it.
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Acknowledgement
I would like to thank respected Mr…….. and Mr. ……..for giving me such a wonderful
opportunity to expand my knowledge for my own branch and giving me guidelines to present a
seminar report. It helped me a lot to realize of what we study for.

Secondly, I would like to thank my parents who patiently helped me as i went through my work
and helped to modify and eliminate some of the irrelevant or un-necessary stuffs.

Thirdly, I would like to thank my friends who helped me to make my work more organized and
well-stacked till the end.

Next, I would thank Microsoft for developing such a wonderful tool like MS Word. It helped
my work a lot to remain error-free.

Last but clearly not the least, I would thank The Almighty for giving me strength to complete
my report on time.
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Content

 Introduction
 What is Rapid Prototyping?
 Why Rapid Prototyping?
 How does Rapid Prototyping Work?
 Applications of Rapid Prototyping
 Basic Process
 The Rapid Prototyping Technique
 Advantages of Rapid Prototyping
 Disadvantage of Rapid Prototyping
 Conclusion
 References
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Introduction

Rapid Prototyping (RP) can be defined as a group of techniques used to quickly fabricate a scale
model of a part or assembly using three-dimensional computer aided design (CAD) data. What is
commonly considered to be the first RP technique, Stereolithography, was developed by 3D
Systems of Valencia, CA, USA. The company was founded in 1986, and since then, a number of
different RP techniques have become available.

Rapid Prototyping has also been referred to as solid free-form manufacturing, computer
automated manufacturing, and layered manufacturing. RP has obvious use as a vehicle for
visualization. In addition, RP models can be used for testing, such as when an airfoil shape is put
into a wind tunnel. RP models can be used to create male models for tooling, such as silicone
rubber molds and investment casts. In some cases, the RP part can be the final part, but typically
the RP material is not strong or accurate enough. When the RP material is suitable, highly
convoluted shapes (including parts nested within parts) can be produced because of the nature of
RP.
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What is Rapid Prototyping?

Rapid Prototyping is the "process of quickly building and evaluating a series of

prototypes" early and often throughout the design process. Prototypes are usually
incomplete examples of what a final product may look like. Each time a prototype is
used, a formative evaluation gathers information for the next, revised prototype. This
cycle continues to refine the product until the final needs and objectives are met. The
following diagram demonstrates the non-linear nature of Rapid Prototyping.
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Why Rapid Prototyping?

The reasons of Rapid Prototyping are

 To increase effective communication.

 To decrease development time.
 To decrease costly mistakes.
 To minimize sustaining engineering changes.
 To extend product lifetime by adding necessary features and eliminating redundant
features early in the design.

Rapid Prototyping decreases development time by allowing corrections to a product to be made

early in the process. By giving engineering, manufacturing, marketing, and purchasing a look at
the product early in the design process, mistakes can be corrected and changes can be made
while they are still inexpensive. The trends in manufacturing industries continue to emphasize
the following:

• Increasing number of variants of products.

• Increasing product complexity.
• Decreasing product lifetime before obsolescence.
• Decreasing delivery time.

Rapid Prototyping improves product development by enabling better communication in a

concurrent engineering environment.
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How does Rapid Prototyping Work?

Rapid Prototyping, also known as 3D printing, is an additive manufacturing technology. The
process begins with taking a virtual design from modeling or computer aided design (CAD)
software. The 3D printing machine reads the data from the CAD drawing and lays down
successive layers of liquid, powder, or sheet material — building up the physical model from a
series of cross sections. These layers, which correspond to the virtual cross section from the
CAD model, are automatically joined together to create the final shape.

Rapid Prototyping uses a standard data interface, implemented as the STL file format, to
translate from the CAD software to the 3D prototyping machine. The STL file approximates the
shape of a part or assembly using triangular facets.

Typically, Rapid Prototyping systems can produce 3D models within a few hours. Yet, this can
vary widely, depending on the type of machine being used and the size and number of models
being produced.
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Applications of Rapid Prototyping

RAPID TOOLING

 Patterns for Sand Casting

 Patterns for Investment Casting

 Pattern for Injection moldings

RAPID MANUFACTURING

 Short productions runs

 Custom made parts

 On-Demand Manufacturing

 Manufacturing of very complex shapes

AEROSPACE & MARINE

 Wind tunnel models

 Functional prototypes

 Boeing’s On-Demand-Manufacturing

AUTOMOTIVE RP SERVICES

 Needed from concept to production level

 Reduced time to market

 Functional testing

 Dies & Molds

BIOMEDICAL APPLICATIONS - I

 Prosthetic parts

 Presurgical planning models

 Use of data from MRI and CT scan to build 3D parts

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 3D visualization for education and training

BIOMEDICAL APPLICATIONS - II

 Customized surgical implants

 Mechanical bone replicas

 Anthropology

 Forensics

ARCHITECTURE

 3D visualization of design space

 Iterations of shape

 Sectioned models

FASHION & JEWELRY

 Shoe Design

 Jewelry

 Pattern for lost wax

 Other castings
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Basic Process
Although several rapid prototyping techniques exist, all employ the same basic five-step process.
The steps are:

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

CAD Model Creation

First, the object to be built is modelled using a Computer-Aided Design (CAD) software
package. Solid modelers, such as Pro/ENGINEER, tend to represent 3-D objects more accurately
than wire-frame modellers such as AutoCAD, and will therefore yield better results. The
designer can use a pre-existing CAD file or may wish to create one expressly for prototyping
purposes. This process is identical for all of the RP build techniques.

Conversion to STL Format

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 three-dimensional surface as an
assembly of planar triangles, "like the facets of a cut jewel." 6 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. Since the .stl format is universal, this process is
identical for all of the RP build techniques.

Slice the 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 pre-processing
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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. Each PR machine manufacturer supplies their own proprietary
pre-processing software.

Layer by Layer Construction

The fourth step is the actual construction of the part. Using one of several techniques (described
in the next section) RP machines build one layer at a time from polymers, paper, or powdered
metal. Most machines are fairly autonomous, needing little human intervention.

Clean and Finish

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.
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The Rapid Prototyping Technique

In the Rapid Prototyping process the 3D CAD data is sliced into thin cross sectional planes by a
computer.

The cross sections are sent from the computer to the rapid prototyping machine which build the
part layer by layer.

The first layer geometry is defined by the shape of the first cross sectional plane generated by the
computer.

It is bonded to a starting base and additional layers are bonded on the top of the first shaped
according to their respective cross sectional planes.

This process is repeated until the prototype is complete.

.Layer by Layer Construction

The fourth step is the actual construction of the part.

RP machines build one layer at a time from polymers, paper, or powdered metal.

Most machines are fairly autonomous, needing little human intervention.

.Clean and Finish

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.

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Advantages of Rapid Prototyping

· Today's automated, toolless, patternless RP systems can directly
produce functional parts in small production quantities.
· Parts produced in this way usually have an accuracy and surface finish inferior to those
made by machining.
· However, some advanced systems are able to
produce near tooling quality parts that are close to or are the final
shape.
· The parts produced, with appropriate post processing, will have
material qualities and properties close to the final product.
· More fundamentally, the time to produce any part --- once the design data
are available --- will be fast, and can be in a matter of hours.

Disadvantage of Rapid Prototyping

One more disadvantage of rapid prototyping is that it may not be suitable for large sized
applications.

The producer may produce an inadequate system that is unable to meet the overall demands of
the organization. Too much involvement of the user might hamper the optimization of the
program.
The producer may be too attached to the program of rapid prototyping, thus it may lead to legal
involvement.
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Conclusion
Finally, the rise of rapid prototyping has spurred progress in traditional subtractive methods as
well. Advances in computerized path planning, numeric control, and machine dynamics are
increasing the speed and accuracy of machining.

Modern CNC machining centers can have spindle speeds of up to 100,000 RPM, with
correspondingly fast feed rates. 34 Such high material removal rates translate into short build
times. For certain applications, particularly metals, machining will continue to be a useful
manufacturing process. Rapid prototyping will not make machining obsolete, but rather
complement it.
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References

 www.google.com
 www.wikipedia.com
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