PRESENTED BY:

AMEER HUZAIN K H
ROLL NO: 11409009
DEPT OF MECHANICAL ENGG MCET
GUIDED BY:

PROF AJIT KUMAR VN(CMDE RETD)
Introduction
Rapid Prototyping Technology is a group
of manufacturing processes that enable
the direct physical realization of 3D
computer models.

This technology converts the 3D
computer data directly to a physical
model.

The presentation gives an overview on
existing major RP techniques and their
applications in engineering fields

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Fig 1: Flying sculpture called the little shining man
created using rapid prototyping technique.

RPT and Rapid Manufacturing (RM)
offers great potential for producing
models and parts.

By this reliability of product can be
increased, investment of time and money
is less risky.

Rapid prototyping is an "additive"
process, combining layers of paper, wax,
or plastic to create a solid object.

In contrast, most machining processes
are "subtractive" processes that remove
material from a solid block.

Most prototypes require from one to
seventy-two hours.



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Fig 2: Rotors made using rapid prototyping techniques
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Verify a design.

Communicate an idea and fix design issues early.

This can prevent costly changes to the hard tool once
the product is in full production.


WHY RAPID PROTOTYPING ??
Creating a prototype early in the design process can help :
The most frequent uses of Rapid
Prototyping include :

Concept models
Design iterations
Engineering evaluations
Form & fit
Presentation models
Market introductions.

The Basic Process
Create a CAD model of the design
# Object to be built is modelled using CAD software.
# Solid modellers like ProE yield better results.
# Existing CAD file may also be used

Convert the CAD model to STL (Standard Tessellation Language)
format
# STL format is the standard of rapid prototyping industry.
# This format represent 3D surface as an assembly of planar triangles and
describes only surface geometry. (without any representation of colour,
texture etc.)

Slice the STL file into thin cross-sectional layers
# Several programmes are available for this.
# STL models are sliced into a number of layers (.01mm to .7mm).
# Orientation size and location are adjusted using the software.
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Construct the model one layer atop another
# RP machine builds one layer at a time from polymers, paper, or powdered
metal.
# Fairly autonomous needing little human intervention.

Clean and finish the model
# Post processing step.
# Prototype may require minor cleaning and surface treatment.

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Rapid Prototyping Techniques
Most commercially available rapid prototyping machines use one
of the five techniques
Stereolithography (SL or SLA)
Laminated object manufacturing
Selective Laser Sintering
Fused deposition modeling
3D ink jet printing
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Fig 3: SL Machine
Stereolithography (SL or SLA)
Builds 3D model from liquid photo sensitive polymers when exposed to UV rays.
Model is built upon a platform situated just below the surface of liquid epoxy or
acrylate resin.
A low power highly focused UV laser traces out the first layer, solidifying model
cross section.
An elevator incrementally lowers the platform into the liquid polymer.
Process is repeated until prototype is complete.
Model is the placed in an UV oven for complete curing.


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Fig 4: Stereolithography
Laminated Object Manufacturing
Layer of adhesive coated sheet materials are bonded to form a prototype.
Paper laminated with heat activated glue is rolled up on spools.
Heated roller applies pressure to bond the paper to the base.
Laser cuts the outline of first layer.
Platform is lowered and fresh material is advanced.
Process is repeated and a roller bonds the layers.

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Fig 5: Laminated Object Manufacturing
Selective Laser Sintering
Uses laser beam to selectively fuse powdered materials such as nylon,
elastomer or metal into a solid object.
Parts are built on a platform which sits below the surface in a bin of heat
fusible powder.
Laser traces the pattern of first layer, sintering it together.
Then platform is lowered, powder is reapplied and process is repeated.

10 Fig 6: Selective Laser Sintering
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Fused Deposition Modelling
Filaments of heated thermoplastics are extruded from a tip that moves in the
platform to form the first layer.
The platform is maintained at a lower temperature, so that the thermoplastic
quickly hardens.
After the platform lowers, the extrusion head deposits a second layer upon
the first.

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Fig 7: Fused Deposition Modelling
3-D Ink Jet Printing
Parts are built upon a platform situated in a
bin full of powder material.

An ink-jet printing head selectively
deposits or "prints" a binder fluid to fuse
the powder together in the desired areas.
Unbound powder remains to support the
part.

The platform is lowered, more powder
added and levelled, and the process
repeated.
Finished parts can be infiltrated with wax,
glue, or other sealants to improve durability
and surface finish.

This process is very fast, and produces parts
with a slightly grainy surface.


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Fig 9: 3-D Ink Jet Printing
Applications of Rapid Prototyping
Engineering
Made use in space stations and space shuttles.
Functional parts in F1 racing cars and fighter jets like F-18.










Rapid Tooling
Tools are made by CNC-machining, electro-discharge machining, or by hand.
All are expensive and time consuming.
Manufacturers would like to incorporate rapid prototyping techniques to speed the
process.
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Medical Applications
Custom-fit, clear plastic aligners (braces) can be produced.
Used in hearing aids to make custom fit shells.
Arts and Archaeology
Selective Laser Sintering with marble powders can help to restore
or duplicate ancient statues.
Conclusion
Modern CNC machines have high removal rates which helps in fast
machining.
For certain applications machining will continue to be a useful
manufacturing process.
One should regard RPT as one more option in the toolkit for manufacturing
parts.
Rapid prototyping will not make machining obsolete, but rather
complement it.
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References
en.wikipedia.org/wiki/Rapid-prototyping
www.protosystech.com/rapid-prototyping.html
www.jharper.demon.co.uk/rptc01.htm
P.M. Pandey, N.V Reddy, S. G. Dhande, Slicing
procedure in layer manufacturing, Rapid prototyping
journal 9(5), 2003, page 274 to 288.
Rapid prototyping: Principles and applications
C.K. Chua
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