3.5.rapid Prototyping

UNIT 3.5.
RAPID PROTOTYPING
ESSENTIAL IDEA:
Rapid prototyping is the production of a physical model of a design using three-dimensional

CAD data.
NATURE OF DESIGN:
The growth in computing power has had a major impact on modelling with computer-aided
manufacture. Rapid software and hardware developments allow new opportunities and
exciting new technologies to create dynamic modelling of ever-greater complexity. Models
can be simulated by designers using software, tested and trialled virtually before sending to
a variety of peripheral machines for prototype manufacture in an ever-increasing range of
materials. The ease of sending this digital data across continents for manufacture of
prototypes has major implications for data and design protection.
AIM OF THE DESIGN:
The increasing effectiveness of rapid prototyping techniques in terms of both cost and
speed enables designers to create complex physical models for testing.
GUIDANCE:
 Recognize the different types of 3D printing techniques

 Understand the advantages and disadvantages of rapid prototyping techniques
CONCEPTS AND PRINCIPLES:
Rapid Prototyping:
 Rapid Prototyping (RP) is the production of a prototype or model using 3D CAD files.
Models are built layer by layer, using plastics, powders, polymers, or metals.
Different technologies are used depending on the material.
 Rapid Prototyping is used to produce one-off or limited-run prototypes and models
for a variety of situations. The speed and efficiency mean they can save costs and
time associated with traditional prototype development.
 This technology is an additive process, whereby material is added or fused to create
a solid form. In this regard, RP technologies produce little to no waste compared to
subtractive processes such as milling and cutting.
 Rapid Prototyping technology also plays an important role in the 4th Industrial
Revolution in that it allows mass customization and greater control by consumers.
1
*In your IA, it is important to identify and describe why a certain process is being selected.
Refer to the design guidelines above to guide you
FUSED DEPOSITION MODELLING (FDM):
The most accessible type of 3D printing technology, FDM involves the laying down of thin
layers of material, usually a type of plastic. The filament is heated in a nozzle and then
"drawn" on layer by layer.
2
a) Filament
b) Extruder (pulls filament) and nozzle (heats up the filament); Moves on the x-axis and y- axis.
c) Printed form (layer upon layer built up)
d) Support structure (printed structures to support overhangs; removed after printing)
e) Build plate (moves up and down on z-axis)
f) Build space
Use Cases:
 Affordable materials and equipment

 Consumer grade technology is accessible and easy to maintain
 Printing functional prototypes
 Variety of materials can be printed
Limitations:
 Relatively slow
Watch the video: https://www.youtube.com/watch?v=GxLjDNrQBgs

[What is FDM 3D Printing Technology | Fused Deposition Modeling Additive Manufacturing]
Figure 1: A variation of FDM, contour crafting, uses liquid ceramic or concrete to create
forms from vessels to buildings.
STEREOLITHOGRAPHY (SLA):
3
In this process an object is created by selectively curing a thin layer of liquid resin with a
laser. A laser heats selected areas of the resin, turning it into a solid. The process continues
until the piece is completed.
Use cases:
 Build functional prototypes
 High resolution allows for very small objects to be printed
 Requires little cleaning up
Limitations:
 Relatively high cost of materials and printers
 Some resins are not ideal for functional prototypes
Watch the video:

https://www.youtube.com/watch?v=8a2xNa AkvLo
[ The Ultimate Guide to Stereolithography: How SLA Works]
LAMINATED OBJECT MANUFACTURING (LOM):
In this process, layers of plastic, metal, or paper are cut with a laser and then stacked on top
of each other. An adhesive is applied between each layer.
Large parts can be made, compared to plastic FDM technologies. The parts can also be
refined, cut, or milled afterwards.
4
SELECTIVE LASER SINTERING (SLS):
In this process a CO2 laser fuses powder, layer by layer, to create a 3D form. Similar to SLA,
a layer of powder is laid down and sintered (burnt) with a laser. The build plate moves down
and another layer of powder is added. This new layer is sintered, and so on until the form is
complete. Unsintered powder is removed from the chamber to reveal a complete 3D form.
The unsintered powder can be reused.
A range of materials can be used in SLS processes, from nylons and polymers, to ceramics
and metal alloys.
Watch the video: https://www.youtube.com/watch?v=9E5MfBAV_tA
[Selective Laser Sintering Technology]
5
USE CASES:
 Little waste as unused powder can be reused

 Low-run production possible
 Printing of functional prototypes
 Printing of metal alloys--no other systems are capable
LIMITATIONS:
 High cost of materials and equipment

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UNIT 3.5.

Rapid prototyping is the production of a physical model of a design using three-dimensional

AIM OF THE DESIGN:

 Recognize the different types of 3D printing techniques

CONCEPTS AND PRINCIPLES:

FUSED DEPOSITION MODELLING (FDM):

c) Printed form (layer upon layer built up)

d) Support structure (printed structures to support overhangs; removed after printing)

e) Build plate (moves up and down on z-axis)

 Affordable materials and equipment

Watch the video: https://www.youtube.com/watch?v=GxLjDNrQBgs

Watch the video:

[ The Ultimate Guide to Stereolithography: How SLA Works]

LAMINATED OBJECT MANUFACTURING (LOM):

Watch the video: https://www.youtube.com/watch?v=9E5MfBAV_tA

[Selective Laser Sintering Technology]

 Little waste as unused powder can be reused

 High cost of materials and equipment

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