Cim Report

Dr.
AMBEDKAR INSTITUTE OF TECHNOLOGY

[An Autonomous Institution, affiliated to VTU, Belgaum and Aided by Government of Karnataka]
Near Jnana Bharathi Campus, Mallathalli, Bangalore-560056
DEPARTMENT OF MECHANICAL ENGINEERING
COMPUTER INTEGRATED
MANUFACTURING
(18ME731)
GROUP ACTIVITY
On
RAPID PROTOTYPE
Submitted By To
DEEPASHREE P S Dr S. SATHISH
1DA20ME015 ASSOCIATE PROFESSOR
RAPID PROTYPING
Rapid prototyping is the fast fabrication of a physical part, model or assembly
using 3D computer aided design (CAD). The creation of the part, model or
assembly is usually completed using additive manufacturing, or more commonly
known as 3D printing.
Rapid prototyping (RP) includes a variety of manufacturing technologies,

although most utilize layered additive manufacturing. However, other
technologies used for RP include high-speed machining, casting, molding and
extruding.
TYPES OF RAPID PROTYPING
• Stereolithography (SLA) or Vat Photopolymerization

This fast and affordable technique was the first successful method of commercial
3D printing. It uses a bath of photosensitive liquid which is solidified layer-by-
layer using a computer-controlled ultra violet (UV) light.
• Selective Laser Sintering (SLS)

Used for both metal and plastic prototyping, SLS uses a powder bed to build a
prototype one layer at a time using a laser to heat and sinter the powdered
material. However, the strength of the parts is not as good as with SLA, while the
surface of the finished product is usually rough and may require secondary work
to finish it.
• Fused Deposition Modelling (FDM) or Material Jetting

This inexpensive, easy-to-use process can be found in most non-industrial
desktop 3D printers. It uses a spool of thermoplastic filament which is melted
inside a printing nozzle barrel before the resulting liquid plastic is laid down
layer-by-layer according to a computer deposition program. While the early
results generally had poor resolution and were weak, this process is improving
rapidly and is fast and cheap, making it ideal for product development.
• Selective Laser Melting (SLM) or Powder Bed Fusion

Often known as powder bed fusion, this process is favoured for making high-
strength, complex parts. Selective Laser Melting is frequently used by the
aerospace, automotive, defence and medical industries. This powder bed based
fusion process uses a fine metal powder which is melted in a layer by layer
manner to build either prototype or production parts using a high-powered laser
or electron beam. Common SLM materials used in RP include titanium,
aluminium, stainless steel and cobalt chrome alloys.
• Laminated Object Manufacturing (LOM) or Sheet
Lamination
This inexpensive process is less sophisticated than SLM or SLS, but it does not
require specially controlled conditions. LOM builds up a series of thin laminates
that have been accurately cut with laser beams or another cutting device to create
the CAD pattern design. Each layer is delivered and bonded on top of the
previous one until the part is complete.
• Digital Light Processing (DLP)
Similar to SLA, this technique also uses the polymerisation of resins which are
cured using a more conventional light source than with SLA. While faster and
cheaper than SLA, DLP often requires the use of support structures and post-
build curing.
An alternative version of this is Continuous Liquid Interface Production (CLIP),

whereby the part is continuously pulled from a vat, without the use of layers. As
the part is pulled from the vat it crosses a light barrier that alters its configuration
to create the desired cross-sectional pattern on the plastic.
• Binder Jetting
This technique allows for one or many parts to be printed at one time, although
the parts produced are not as strong as those created using SLS. Binder
Jetting uses a powder bed onto which nozzles spray micro-fine droplets of a
liquid to bond the powder particles together to form a layer of the part.
Each layer may then compacted by a roller before the next layer of powder is
laid down and the process begins again. When complete the part may be cured in
an oven to burn off the binding agent and fuse the powder into a coherent part.
APPLICATIONS
Product designers use this process for rapid manufacturing of representative
prototype parts. This can aid visualisation, design and development of the
manufacturing process ahead of mass production.
Originally, rapid prototyping was used to create parts and scale models for
the automotive industry although it has since been taken up by a wide range of
applications, across multiple industries such as medical and aerospace.
Rapid tooling is another application of RP, whereby a part, such as an injection

mould plug or ultrasound sensor wedge, is made and used as a tool in another
process.
ADVANTAGES
• There are a number of rapid prototyping advantages, such as being able to
gain a more complete picture of how a product will look or perform in the
early stage of the design and manufacturing cycle, allowing changes or
improvements to be implemented earlier in the process. The time this takes
can vary from a few days to a number of months, depending on the methods
used.
• RP is a very cost-effective way to prototype products as it is an automated
process, requiring less staff to operate. This process is also extremely precise,
being able to use computer aided design (CAD) to help reduce the amount of
material wastage and does not require special tools for prototyping each new
product. Being able to act quickly and solve any problems also reduces the
risk of costly errors during the manufacturing stage.
• Rapid Prototyping helps designers present new concepts to board members,
clients or investors so that they can understand and approve a development or
product. This visualisation can also allow designers to gain ready feedback
from customers and clients based on an actual physical product rather than a
concept.
• As rapid prototyping is an iterative process it allows customer requirements to
be incorporated into designs cost-effectively. The process cuts out the need
for customised products to be designed from scratch while providing greater
choice and flexibility for customers.
DISADVANTAGES
• It’s not as useful for complex products.

Rapid prototyping may not be the best method for testing if
the prototypes are not close enough in appearance and
functionality to the final product. For example, it’s difficult to
make a functional prototype if you have a physical product with
many moving parts (like a new type of engine) or if your website
or video game relies on a unique, difficult-to-code custom
mechanic.
• It costs more upfront.

The more prototypes you test before manufacturing your
product, the more expensive the product development
process will be. Thorough prototyping will likely save you
money in the long run, but it will require more capital—
especially if you’re using new rapid prototyping processes that
are still relatively costly.
• It limits the materials at your disposal.

While rapid prototyping can be great for testing a proof of
concept, it won’t give you a sense of the strength, colour, or
surface finish of the final product.

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Dr.

AMBEDKAR INSTITUTE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

Rapid prototyping (RP) includes a variety of manufacturing technologies,

• Stereolithography (SLA) or Vat Photopolymerization

• Selective Laser Sintering (SLS)

• Fused Deposition Modelling (FDM) or Material Jetting

• Selective Laser Melting (SLM) or Powder Bed Fusion

• Digital Light Processing (DLP)

An alternative version of this is Continuous Liquid Interface Production (CLIP),

Rapid tooling is another application of RP, whereby a part, such as an injection

• It’s not as useful for complex products.

• It costs more upfront.

• It limits the materials at your disposal.

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