Rapid Prototyping

Vignesh.R1#, Vignesh.S2*
#
Department of Automobile, PSG College of Technology, Coimbatore
*
Department of Mechanical, PSG College of Technology, Coimbatore

Address
1
[email protected]
2
[email protected]
Abstract— The term rapid prototyping (RP) refers to a class of  Create a CAD model of the design.
technologies that can automatically construct physical models  Convert the CAD model to STL (Stereo
from Computer-Aided Design (CAD) data. It is also called Lithography) format.
Desktop Manufacturing or Freeform Fabrication. These
 Slice the STL file into thin cross-sectional layers.
technologies enable us to make even complex prototypes that act
as an excellent visual aid to communicate with co-workers and
 Construct the model one layer above another.
customers. These prototypes are also used for design testing.  Clean and finish the model.

1) CAD model creation:

Keywords—Introduction–Methodology of rapid processing–
First, the object to be built is modeled using a
CAD Model –RP Techniques–SLA–SLS–LOM–FDM–SGC–
COMPUTER-AIDED-DESIGN (CAD) software package.
Applications–Advantages–Disadvantages–Economical–
The designer can even use a pre-existing CAD file or may
Conclusion
wish to create one specifically for prototyping purposes. The
process is identical for all of the Rapid Prototyping build
techniques.
I. INTRODUCTION
Rapid prototyping is a modelling process used in product 2) Conversion to STL Format:
design in which a CAD drawing of a part is processed to The various CAD packages use a number of different
create a file of the part in slices, and then a part is built by algorithms to represent solid objects. To establish consistency,
depositing layers upon the basic layer of the material. It is an the STL (stereo lithography, the first RP technique) format has
automatic construction of physical objects using additive been adopted as the standard of the rapid prototyping industry.
manufacturing technology. With additive manufacturing, the The second step, therefore, is to convert the CAD file into
machine reads in data from a CAD drawing and lays down STL format. This format represents a threedimensional
successive layers of liquid, powder, or sheet material, and in surface as an assembly of planar triangles, "like the facets of a
this way builds up the model from a series of cross sections. cut jewel." The file contains the coordinates of the vertices
These layers, which correspond to the virtual cross section and the direction of the outward normal of each
from the CAD model, are joined together or fused triangle.Because STL files use planar elements, they cannot
automatically to create the final shape. The primary advantage represent curved surfaces exactly. Increasing the number of
to additive fabrication is its ability to create almost any shape triangles improves the approximation, but at the cost of bigger
or geometric feature. file size. Large, complicated files require more time to pre-
process and build, so the designer must balance accuracy with
Rapid Prototyping is also known as manageability to produce a useful STL file. Since the .stl
 Generative Manufacturing. format is universal, this process is identical for all of the RP
 Layered Manufacturing. build techniques.
 Solid free-form Manufacturing.
 Tool less Model Making 3) Slice the STL file:
In the third step, a pre-processing program prepares the
Why rapid prototyping? STL file to be built. Several programs are available, and most
 To increase effective communication. allow the user to adjust the size, location and orientation of the
 To decrease development time. model. Build orientation is important for several reasons.
 To decrease costly mistakes First, properties of rapid prototypes vary from one coordinate
 To minimize sustaining engineering changes. direction to another. For example, prototypes are usually
 To extend product lifetime by adding necessary weaker and less accurate in the z (vertical) direction than in
features and eliminating redundant features early in the x-y plane. In addition, part orientation partially determines
the design. the amount of time required to build the model. Placing the
 To increase productivity shortest dimension in the z direction reduces the number of
 To help in better visualization of designs. layers, thereby shortening build time. The pre-processing
 To employ latest and new technology. software slices the STL model into a number of layers from
0.01 mm to 0.7 mm thick, depending on the build technique.
A. Rapid Prototyping Techniques The program may also generate an auxiliary structure to
support the model during the build. Supports are useful for
 Stereo lithography (SLA) delicate features such as overhangs, internal cavities, and thin-
 Selective laser Sintering (SLS) walled sections. Each PR machine manufacturer supplies their
 Laminated Object Manufacturing (LOM) own proprietary pre-processing software.
 Fused Deposition Modeling (FDM)
 Solid Ground Curing (SGC) 4) Layer by Layer Construction:
The fourth step is the actual construction of the part.
B. Methodology of rapid processing 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.

5) 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.

II. RAPID PROTOTYPING TECHNIQUES

A. Stereolithography
The first commercially available rapid prototyping
technique and the most widely used technique today.
Sterolithography produces prototype parts layer by layer using
any solid-state laser (carbon dioxide laser) to trace the cross-
sectional slice information of a 3-D CAD data onto the surface
of container of LIQUID PHOTOPOLYMER or Photopolymer
resin. These materials quickly solidify when laser beam falls
on them. This self adhesive property of the material helps in
building up the 3-D object which is similar to the 3-D CAD
drawing. To finish the work, uncured resin is removed and the
model is post-cured to fully cure the resin. During fabrication,
if extremities of the part become too weak, it may be
necessary to use supports to prop up the model. Such supports
can be generated by the program that creates the slices, and Fig. 1 Stereolithography technique
the supports are only used for fabrication. After building,
parts are cleaned of excess resin by immersion in a chemical 1) Pros:
bath and then cured in a UV oven. This processes is repeated  Functional part can be created within one day
until the desired shape according to the CAD model is  Uses a light-sensitive liquid polymer.
obtained.  Requires post-curing since laser is not of enough
power to completely cure.
 Long-term curing can lead to warping.
 Parts are quite brittle and have a tacky surface.
 Can be used as patterns for Injection moulding,
thermoforming.
 Support structures are essentially required.
 Process is simple: There are no milling or masking
steps required.
 Uncured material can be toxic.
 Ventilation is a must.

2) Cons:
 The process is often expensive.
 The photo-curable resin costs anywhere from $80 to
$210 per litre.
 A stereolithography machine can cost from about
$100,000 to more than $500,000.

B. Selective Laser Sintering

This technique uses the heat of a Carbon-di-oxide laser to
“sinter” or melt powdered thermoplastic materials in layers.
The laser is guided across the part bed by scanning system and paper is pressed on to the base using a heated roller. A
selectively sinters or melts the materials based on cross- focused laser cuts the outline of the first layer into the paper
sectional slice information of the 3-D CAD data file. These and then crosshatches the excess area. The next layer is built
are built in an atmosphere that controls the thermal on top of the first layer in the same manner. The hatched parts
distribution and thus requires less laser power; the powder in (excess area) are removed after the final layer is bonded. The
build chamber acts as a support for the parts during final model has a wood like texture and since it is made of
fabrication. Parts produced using SLS have a greater Strength paper the model has to be varnished to prevent moisture
than SLA. damage.

Fig. 3 Laminated Object Manufacturing technique

Fig. 2 Selective Laser Sintering technique

1) Pros: 1) Pros:
 Stronger than SLA.  The model is formed by layers of glue backed paper.
 Laser beam selectively fuses powder materials:  Low cost: Due to easy availability of raw material.
nylon, elastomer and soon metal  Large parts: Due to the absence of chemical reaction.
 Process is simple: no need of milling and masking  Models should be sealed to prevent entry of
steps. moisture.
 Living hinges are possible with thermoplastic-like  Ensure that models have a wood-like texture before
materials. sealing.
 Powdery, porous surface unless sealant is used.
Sealant also helps in strengthening parts. 2) Cons:
 Uncured material is easily removed after a build by  Not enough bonding between layers.
brushing or blowing it off.  Poor surface finish
 Difficulty in produci.ng hollow parts.
2) Cons:
 Potential accuracy of parts is limited to size of D. Fused Deposition Modeling
powdered materials. The process involves heating a filament of thermoplastic
 Rough part surface. polymer and squeezing it out like toothpaste from a tube to
 Heating up and cooling down procedures are time form the RP layers. The material comes out through a nozzle
consuming. and it can be moved in horizontal and vertical directions using
 Performing the sintering process is required in a COMPUTER-AIDED-MANUFACTURING (CAM) software
nitrogen atmosphere packages. This technology is generally used with
polycarbonates, polycaprolactone, polyphenylsulfones and
waxes. Generally water soluble materials are used as
C. Laminated Object Manufacturing temporary supports.
In LOM layers of adhesive-coated sheet material are
bonded together to form a prototype. The model material
consists of paper laminated with heat-activated glue. The
 is similar to that of SLA technique but in this case each resin
layer is hardened as soon as it is produced.

Fig. 5 Solid Ground Curing technique

Fig. 4 Fused Deposition Modeling technique

1) Pros: 1) Pros:
 Standard engineering thermoplastics, such as ABS,  High speed allows production-like fabrication of
can be used to produce structurally functional many parts or large parts.
models.  No post cure is needed.
 Two build materials can be used, and lattice work  Creates a lot of waste.
interiors are an option in FDM.
 Filament of heated thermoplastic polymer is 2) Cons:
squeezed out.  Large, heavy machine which requires high
 Thermoplastic is automatically cooled rapidly since maintenance.
the platform is maintained at lower temperature.  Attended operation (limited).
 Not as predominant as SLA and SLS but it holds a  Material limitations (two photopolymers).
place in the future due to the desirable material  Removal of wax can be difficult and time consuming
properties.  Waste wax is non-recoverable and limited
recyclability of resins.
2) Cons:
 Precise slots, domes, ribs and thin wall thickness III. APPLICATIONS
cannot be formed.  Prototyping
 Extrusion width limits geometry to be formed.  Rapid Tooling
 Process is suitable only for smaller parts at the  Rapid Manufacturing
moment.  Heterogeneous Modelling

E. Solid Ground Curing

Solid Ground Curing utilizes the general IV. ADVANTAGES
process of hardening of photopolymers by a
complete lighting and hardening of the entire  Objects having complex geometry can be easily
surface, using specially prepared masks. A manufactured.
photopolymer liquid in each layer is covered with  Better surface finish.
a photo mask and cured for several seconds by a  Considerable reduction in production time.
strong ultraviolet lamp. The exposed liquid  Less wastage of build-materials.
polymer is then removed and the  RP manufacturers are dramatically reducing build
voids are filled with wax to support the next layer. It time.
 V. DISADVANTAGES

 The polymer material has to be in a special form to

be used for prototyping.
 Less tensile strength.
 Not economical for manufacture of simple designs.
 Not suitable for small-scale production.
 Physical properties of the part change with method of
manufacture.
 Since the objects are made layer by layer there is a
“Stair Stepping Effect”.

VI. CONCLUSIONS

Rapid prototyping is starting to change the way companies

design and build products. Today’s commercially available
machines are accurate to ~0.08 millimetres in the x-y plane,
but less in the z (vertical) direction. Improvements in laser
optics and motor control should increase accuracy in all three
directions. In addition, RP companies are developing new
polymers that will be less prone to curing and temperature-
induced war page.
The introduction of non-polymeric materials, including
metals, ceramics, and composites, represents another much
anticipated development. These materials would allow RP
users to produce functional parts. Today’s plastic prototypes
work well for visualization and fit tests, but they are often too
weak for function testing. More rugged materials would yield
prototypes that could be subjected to actual service conditions.
In addition, metal and composite materials will greatly expand
the range of products that can be made by rapid
manufacturing.
The United States currently dominates the field, but
Germany, Japan, and Israel are making inroads. In time RP
will spread to less technologically developed countries as
well. With more people and countries in the field, RP’s
growth will accelerate further.

REFERENCES
[1]R.A.Lindberg, Processes and Materials of Manufacture
[2]Serope Kalpakjian & Steven R Schimid, Manufacturing Process for Engg.
Materials
[3]R. K Jain, Production Technology
[4]O.P.Khanna & Lal, Production Technology
[5]www.me.psu.edu
[6]www.materialise.com/rapid-prototyping
[7]www.efunda.com/processes/rapid_prototyping/intro.cfm