New Horizon Institute of Technology and

Management

COURSE PROJECT REPORT ON:

RAPID PROTOTYPING AND MANUFACTURING

TECHNOLOGIES

ADITYA HEMANT SONKUSARE (Roll No:- 65)

SHREYASH ABHAY KAMBLE (Roll No:- 27)
SIDDHARTH GOWRI VAIYAPURI (Roll No:- 72)

PROJECT COORDINATOR:
PROF. GANESH KOLEKAR

ACADEMIC YEAR
2021-2022

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 1. INTRODUCTION

Rapid prototyping (RP) refers to a class of RAPID MANUFACTURING

technologies that can ‘rapidly’ construct TECHNOLOGY:
physical models from computer aided design
Rapid manufacturing refers to the use of
(CAD) data. It is also known as a class of parts built by rapid prototyping systems as
technologies and is defined, for the purpose patterns in further manufacturing processes.
of primer, as a ‘diverse’ set of technological Rapid manufacturing techniques may be
used to fabricate metallic components, they
tools and resources that can automatically may be used to fabricate polymeric parts in a
fabricate physical models from Computer range of common engineering plastics, or
Aided Design (CAD) data. Having their own they may be used to generate multiple
strengths and compatibility, there are at least copies of a part from one master. Examples
abound in the use of RPT products as
six different rapid prototyping techniques patterns in silicone rubber moulding,
that are commercially available each with investment and sand castings
their own strengths and compatibility. Many
companies produce machines which can RAPID PROTOTYPE AS DESIGN
fabricate a physical 3D model out of
different materials like metal, plastic and The recent advent of the latest rapid
paper. Normally, the machines run prototyping, computer aided design (CAD),
unattended and from CAD data they rapidly computer aided engineering (CAE) and
produce precise and accurate models with no computer aided manufacturing (CAM)
need for a highly skilled machinist. Hence, technologies has added a new twist to the
these machines are generally called Rapid traditional prototype as design process. It is
Prototyping machines as the center of the now transforming from a `prototype as
rapid prototyping industry. These methods design' process into a `Rapid Prototype as
are unique in that layer-by-layer they add Design' process. This new generation of
and bond materials to form objects. Such tools now allows engineers to, for example,
methods are generally known as free form relatively easily perform complex finite
fabrication (FFF), layered manufacturing element analysis (FEA) calculations on their
and solid freeform fabrication (SFF). In this products, to test for any thermal or structural
paper, the design process methodology is problems, and even to simulate how plastic
also explained and simplified. It is a guide to may flow through an injection molding tool
the logical procedure of introducing RP into during manufacturing. Physical prototypes
a mechanical engineering design process play a great role in product development as
and glean maximum benefit from it. Finally, they are a means of demonstrating scale and
the case studies illustrate the benefits of this realism in a way that paper drawings, and
technology applied to the mechanical field. even computer 3D models, cannot. The
translation from two-dimensional to
three-dimensional representations is a key
stage in product development. The
progression of prototypes can be A Case

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Study of Rapid Prototype as Design in thin slices (generally ranging from 0.1 mm
Educational Engineering Projects 351 seen to 0.25 mm per slice depending on the
as going from two-dimensional to three technology and machine used). The rapid
dimensional on-screen, to three-dimensional prototyping machine then builds the model
physical models. Only a three-dimensional one slice at a time, with each subsequent
physical model can effectively achieve the slice being built directly on the previous
real suitability of a physical product. There one. The technologies differ mainly in terms
are invariably large differences in perception of the materials they use to build the part,
between a user seeing a traditional CAD and the process used for creating each slice
model only and then seeing a real physical of the model.
working model. The additional tactile,
haptic and true three-dimensional perception The six RP techniques available are as
produce two completely different responses follows:
in the user. The overall design process now • Stereolithography (SLA)
looks somewhat as follows: Initial • Laminated Object Manufacture (LOM)
conceptual sketches are still often done in • Selective Laser Sintering (SLS)
2D, both on paper and on the computer. • Fused deposition Modeling (FDM)
More advanced conceptual design and • Solid Ground Curing (SGC)
engineering design models are then • 3D Inkjet Printing
produced using 3D CAD software. This
produces a virtual model that can be rotated, II. DESCRIPTION OF TECHNIQUES
zoomed in on, measured and manipulated
on-screen. From this 3D computer model, a 2.1. Stereolithography:
physical rapid prototype can be produced. Stereo Lithography uses a concept of turning
Traditionally, the only way to produce a real, photosensitive liquid resin into a solid
physical model was to either use a polymer when exposed to ultraviolet light.
subtractive technology such as CNC The process takes place just at the surface
(computer numerically controlled) because of the absorption and scattering of
machining or to produce expensive tooling the beam, which forms voxels of solid
into which the part could be injection polymers. As shown in figure 1, the required
molded. Both these methods were both time model is erected upon a platform placed just
consuming and expensive. The latest below the surface in a repository of liquid
generation of rapid prototyping epoxy or acrylate resin. A UV laser, which
technologies, such as stereolithography is highly focused, outlines the first layer,
(SLA), selective laser sintering (SLS) and solidifying the model’s cross section while
fused deposition modeling (FDM) now leaving the remaining space liquid.
allow physical prototypes to be produced
within hours rather than days. The rapid
prototyping process begins by taking a 3D
computer generated file and slicing it up into

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 the left-over space, breaking up the extra
material, which makes it easier to remove
during post-processing. The excess material
offers admirable support for overhangs and
thin-walled sections during the build. After
the first layer is cut, the stage comes down,
making way for fresh material. The platform
rises again, slightly below the previous
height, and the second layer is bonded to the
first layer by a roller, and the second layer is
cut by the laser. This process is repeated as
needed to construct the part, whose texture
After that, an elevator steadily lowers the will be wood-like. Because the models are
platform into the liquid polymer. The composed of paper, they must be closed and
solidified layer is repainted by a sweeper completed with paint or varnish to check
with liquid, and the laser outlines the second moisture damage.
layer over the first. The prototype is
completed by repeating this process. Later,
the solid part is separated from the
repository and washed clean of excess
liquid. The complete curing is done by
placing the model in an ultraviolet oven.

2.2. Laminated Object Manufacturing

(LOM):
In Laminated Object Manufacturing (LOM),
a prototype is formed by attaching layers of
adhesive coated sheet material. A
cross-sectional outline of the layer is cut 2.3. Selective Laser Sintering (SLS):
using lasers and a new layer is attached to In the Selective Laser Sintering (SLS)
the previously cut layer and again a new process, a laser beam is used to selectively
cross-section is produced. As shown in combine powdered materials into a solid
figure 2, a feeder/collector mechanism object. With the aim of minimizing thermal
progresses the sheet upon the build stage, distortion (curling) and to make sure the
where a base has been constructed from previous layer is fused, the temperature of
paper and double-sided foam tape. the complete bed is raised to just below its
Afterward, pressure is applied by a heated melting point by infrared heating. The laser
roller which bonds the paper to the base. is modified to affect those grains which are
The outline of the first layer is cut into the in direct contact with the beam. Once the
paper by a focused laser and then eliminates curing of a slice is done by laser scanning, a

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counter rotating roller spreads a covering of and can be broken easily once the complete
powder evenly over the build area. In this part is deposited and is removed from
process the left-over powder in each layer substrate. In more recent FDM technology,
helps to support the structure during the water-soluble support structure material is
build. Once the model is complete it is used. Support structure can be deposited
cleaned away and can be recycled. The with lesser density as compared to part
schematic diagram of a typical SLS density by providing air gaps between two
apparatus is given in figure 3 below. consecutive roads.

2.4. Fused Deposition Modeling

In Fused Deposition Modeling (FDM)
process a movable (x-y movement) nozzle 2.5. 3D Inkjet Printing:
deposits a thread of molten polymeric Ink-Jet Printing represents an entire category
material onto a substrate. The build material of machines that make use of ink-jet
is heated slightly above (approximately technology and the first was 3D Printing.
0.5oC) its melting temperature so that it This process is comparable to selective laser
solidifies within a very short time sintering. Here an inkjet head replaces the
(approximately 0.1 seconds) after extrusion laser. The "three dimensional printers''
and cold-welds to the previous layer as permit designers to swiftly form tangible
shown in figure 4. Various important factors prototypes of their designs. The
need to be considered and are steady nozzle three-dimensional printing system takes
and material extrusion rates, addition of input CAD files in formats like
support structures for overhanging features Stereolithography (STL), Drawing
and speed of the nozzle head, which affects Exchange Format (DXF) and Hewlett
the slice thickness. More recent FDM Packard Graphics Language (HPGL). As in
systems include two nozzles, one for part other systems, sliced formation is then
material and other for support material. The created. Powder is provided on a platform
support material is relatively of poor quality and a roller spreads the powder. The powder
is evenly layered. The printing head in the

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inkjet printer discharges jets of binder to First Stage: - The first stage is centered on
bond powder material. Unbound powder is the idea of the designer. This is usually
allowed to support the part. The platform is conceived on a handmade drawing or on the
brought down and more powder is added computer. The main dimensions and other
and leveled. The process is repeated several constraints play a factor as to how the initial
times. The schematic representation of this idea will develop into the finished article.
process is given in figure 6. Improved
durability and surface finish can be obtained Second stage: - The second stage is
by infusing the finished parts with wax, centered on the modeling in the computer
cyanoacrylate (CA) glue or other sealants. software. A number of software packages
One of the main advantage of 3DP is that like CATIA and CREO can be used for
support structure is not needed modeling. These softwares tend to construct
3D models more accurately compared to
modelers such as AutoCAD. However, 2D
models can be used as a base to construct
the 3D model more accurately.

Third stage: - The Stereolithography (STL)

format has been made as the quotidian of the
Rapid Prototyping industry. Hence this next
step is based on the conversion of the CAD
file into STL format. Because STL uses
planar elements, they cannot directly create
a curved surface exactly. Bigger, more
complex files require more time to
preprocess, so the designer should take into
account both the precision of the model and
its manageability. A pre-processing software
slices the STL model into a number of layers
III. DESIGN PROCESS
from 0.01 mm to 0.7 mm thick. The
METHODOLOGY:
program may also create an auxiliary
structure to support the model during the
This section provides an overview of the
build. A physical model allows the designer
methodology of the rapid prototyping
to observe if the model is what he pictured
process from the nascent stages of the idea
initially. He can still edit the model, if
when it is conceived to the completion of the
necessary.
actual, physical model itself. Figure 7
displays the step-by-step process by which
Fourth stage: - This stage is centered on
the design process is carried out. This is
detailed design and construction of the part.
divided into four stages:-
Using polymers, paper or powdered metal,

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RP machines are able to build parts and computer-aided-design (CAD)
layer-by-layer using one of the rapid software are applied.
prototyping techniques. The final step to this ● Minimal waste: Conventional
is post processing. Here, the prototype is methods such as CNC machining
detached from the machine and undergoes produce a lot of waste. With rapid
cleaning and surface treatment. Further prototyping, the only material used is
improvements to the aesthetics of the that which goes toward building the
prototype can be carried out. part initially designed with CAD
software.
● Visualizing design concepts:
Product designs can be realized
quickly, as a component’s properties
and design can be more easily
assessed. A 3D model helps you
understand its look and feel and
allows designers to provide a
realistic proof of concept to clients.
● Instant changes: Continual
improvements in design are possible
in near real-time, based on customer
feedback. Product testing is
simplified as well, eliminating
design flaws and improving time to
market.
● Customization: Rapid prototyping
applications are practically
Advantages of Rapid Prototyping: unlimited. Manufacturers can
produce custom products without the
Additive manufacturing has few limitations need for special tools, while custom
regarding part form. While traditional options can be implemented with just
production requires removing vast amounts minor tweaks to CAD models.
of material, such is not the case here,
yielding benefits such as:
Disadvantages of Rapid Prototyping:

● Cost/time savings: Eliminating the

need to create tooling and molds ● Lack of accuracy.
saves costs and time. When ● Problems in matching strength and
adjustments to part geometry are surface finish
needed, the same printing equipment ● Additional initial costs

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 ● Some rapid prototyping processes provides a platform for researchers and
are not economical product manufacturers to create and spread
● Requires skilled labor to create a awareness of rapid prototyping technology
perfect model as per design for creating products of contoured and
● Limited range of materials that can complex shapes in various fields of
be used applications. Rapid prototyping will not
make machining archaic, but rather
● It may also result in insufficient
supplement and further it. In this research
analysis
work, the use of RP as a tool for
manufacturing assembly training and
validation is successfully implemented. It
was found out that RP in the assembly
CONCLUSION: process offers many advantages such as
physical touch, actual tolerances, sequence
This paper provides an insight into RP of assembly steps, etc. that are missing in
technology and underscores its evolving other methods. A user-based study will be
ability to decrease the cost accrued and the carried out in the future; in which different
time taken to build structures, improve persons will be trained, using various
surface finish, part strength and reduction of training mediums (such as, conventional 2D
layer thickness. Classification of RP drawings, virtual reality environments, etc.).
techniques is given, and explained. Design Then they will perform the assembly of an
process methodology is covered, and case actual product. Training effectiveness and
studies are presented to highlight the transfer of training will be assessed. In
efficiency in which projects are carried out addition, the limitation of the digital
through rapid prototyping. Although it was assembly process or other multimedia
initially conceived as conducive to medical support in terms of cost and training time
applications or in arts and architecture, the will be further investigated to support
mechanical field can also benefit from this positioning and the profitability of physical
technology. The use of Rapid Prototyping prototyping technology.
models will provide a rapid capability in the
determination of the material characteristics
of preliminary designs. It can be used in the
nascent design stages to construct a
conceptual model or in later stages when the
finer details and the finishing touches need
to be applied. In time, the usage of rapid
prototyping technology will become
widespread and quotidian for many design
engineers in conjunction with the
conventional existing ways of creating scale
models of mechanical parts. This paper