Rapidprototyping

Rapid Prototyping
Systems
The term rapid prototyping (RP) refers to a class of

technologies that can automatically construct
physical models from Computer-Aided Design
(CAD) data.
These "three dimensional printers" allow designers
to quickly create tangible prototypes of their
designs, rather than just two-dimensional pictures.
http://www.me.psu.edu/lamancusa/rapidpro/primer/chapter2.htm
This material is based upon work supported by the National Science Foundation under Grant No.
0402616. Any opinions, findings and conclusions or recommendations expressed in this material
are those of the author(s) and do not necessarily reflect the view of the National Science
Foundation (NSF).
Rapid Prototyping
Systems
Of course, "rapid" is a relative term.
Most prototypes require from three to seventy-two

hours to build, depending on the size and complexity of
the object.
This may seem slow, but it is much faster than the
weeks or months required to make a prototype by
traditional means such as machining.
These dramatic time savings allow manufacturers to
bring products to market faster and more cheaply.
Rapid Prototyping Systems

Such models have numerous uses:
Excellent visual aids for communicating
Prototypes can be used for design testing.
Used to make tooling
Used to make production-quality parts

All RP techniques employ the same basic fivestep process.
1.
Create a CAD model of the design
2.
Convert the CAD model to STL format (stereolithography)
3.
Slice the STL file into thin cross-sectional layers
4.
Construct the model one layer atop another
5.
Clean and finish the model
Rapid Prototyping
Systems
CAD Model Creation:
First, the object to be built is modeled using a ComputerAided Design (CAD) software package.
Solid modelers, such as Pro/ENGINEER, tend to
represent 3-D objects more accurately than wire-frame
modelers such as AutoCAD, and will therefore yield
better results.
This process is identical for all of the RP build
techniques.

Conversion to STL Format:
To establish consistency, the STL (stereolithography, the
first RP technique) format has been adopted as the
standard of the rapid prototyping industry.
The second step, therefore, is to convert the CAD file
into STL format. This format represents a threedimensional surface as an assembly of planar triangles
STL files use planar elements, they cannot represent
curved surfaces exactly. Increasing the number of
triangles improves the approximation

Slice the STL File:
In the third step, a pre-processing program prepares the
STL file to be built.
The pre-processing software slices the STL model into a
number of layers from 0.01 mm to 0.7 mm thick,
depending on the build technique.
The program may also generate an auxiliary structure to
support the model during the build. Supports are useful
for delicate features such as overhangs, internal cavities,
and thin-walled sections.

Layer by Layer Construction:
The fourth step is the actual construction of the
part.
RP machines build one layer at a time from
polymers, paper, or powdered metal.
Most machines are fairly autonomous, needing
little human intervention.
Rapid Prototyping
Systems
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.

Stereolithography
Patented in 1986, stereolithography started
the rapid prototyping revolution. The
technique builds three-dimensional models
from liquid photosensitive polymers that
solidify when exposed to ultraviolet light.
The Stereolithography Machine
PT CAM uses a
stereolithography machine
produced by 3-D Systems and
shown here:
http://computer.howstuffworks.com/stereolith1.htm
Picture of a statue using

Stereolithography
http://home.att.net/~castleisland/faq/faq250.htm
Laser Cutting
Laser cutting is just one of a number of
processes used to cut metal into desired
shapes. Other typical cutting processes
include plasma cutting, flame or oxyfuel
cutting, water jet cutting, and even metal
stamping which competes on certain
levels
http://www.teskolaser.com/tips.html
Benefits of Laser
Cutting
There are many benefits to laser-cutting service
providers that directly translate to the process endusers. Some are:

Improved parts production and reduced part distortion as
a result of the small heat affected zones (HAZ)
Greatly reduced tool wear due to the non-contact cutting
process.
Increased saving due to more efficient utilization of
materials
Reduced inventory due to typical efficiency of production
runs.
Improved part appearance since a laser's minimal Heat
Affected Zone eliminates distortion.
http://www.teskolaser.com/laser_cutting1.html
Examples of Laser
Cutting
Pictures from:
http://www.tysica.co.za/laserpics.html
Fused Deposition
Modeling
(FDM) is a solid-based rapid prototyping method that
extrudes material, layer-by-layer, to build a model.
A thread of plastic is fed into an extrusion head, where it is

heated into a semi-liquid state and extruded through a very
small hole onto the previous layer of material.
Support material is also laid down in a similar manner.

http://www.padtinc.com/rm/fdm/default.htm
Advantages of FDM
Process
High strength
High strength
Cost-effective
Waterproof
ABS material
Multiple material colors
Fused Deposition
Modeling
FDM 2000 Specifications

Build Volume: 10" x 10" x 10"
Materials:ABS, Casting Wax
Build Step Size: 0.005" to 0.030"
Prodigy Specifications
Build Volume: 8" x 8" x 10"
Materials: ABS, Casting Wax
Build Step Size: 0.007", 0.010", 0.013"
Up to 4x faster than the FDM 2000
Examples of
Fused Deposition Modeling
Laminated Object
Manufacture
As the name implies the process
laminates thin sheets of film (paper or
plastic)
The laser has only to cut/scan the
periphery of each layer
http://www.foundryonline.com/laminate.htm
Laminated Object
Manufacture
The process:
The build material (paper with a thermo-setting resin glue

on its under side) is stretched from a supply roller across
an anvil or platform to a take- up roller on the other side.
A heated roller passes over the paper bonding it to the
platform or previous layer.
A laser, focused to penetrate through one thickness of
paper cuts the profile of that layer. The excess paper
around and inside the model is etched into small squares
to facilitate its removal.
Laminated Object
Manufacture
The process continued:
The process of gluing and cutting continuous layer
by layer until the model is complete.
To reduce the build time, double or even triple layers
are cut at one time which increases the size of the
steps on curved surfaces and the post processing
necessary to smooth those surfaces.
Laminated Object
Manufacture
Applications of LOM objects:
LOM objects are durable, multilayered structures which

can be machined, sanded, polished, coated and painted.
Used as precise patterns for secondary tooling
processes such as rubber moulding, sand casting and
direct investment casting.
Used for limited testing.
Used as visual models.
Laminated Object
Manufacture
http://www.webarchive.org.uk/pan/10778/20050203/www.uclan.ac.uk/clt/calm/lom.htm
Examples of Laminated
Object Manufacture
Wind Turbine
In this case the LOM
process was initially used
to check the CAD
geometry: subsequently
the model was used as a
sand casting pattern. The
picture opposite shows 5
identical blades
assembled around an SLA
hub.
http://www.imcuk.org/rapid/lom_example.html
Examples of Laminated
Object Manufacture
A LOM model was
built for a customer
who required a
prototype to test the
fit and operation of
internal components
in an electrical
housing.
http://www.imcuk.org/rapid/lom_example.html
Standards to be
Covered:
2.AA
2.BB
10.I
10.J

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Rapid Prototyping

The term rapid prototyping (RP) refers to a class of

Of course, "rapid" is a relative term.

Most prototypes require from three to seventy-two

Rapid Prototyping Systems

Rapid Prototyping Systems

Create a CAD model of the design

Convert the CAD model to STL format (stereolithography)

Slice the STL file into thin cross-sectional layers

Construct the model one layer atop another

Clean and finish the model

CAD Model Creation:

Rapid Prototyping Systems

Rapid Prototyping Systems

Rapid Prototyping Systems

The final step is post-processing. This involves removing

Rapid Prototyping Systems

The Stereolithography Machine

Picture of a statue using

providers that directly translate to the process endusers. Some are:

A thread of plastic is fed into an extrusion head, where it is

Support material is also laid down in a similar manner.

FDM 2000 Specifications

The build material (paper with a thermo-setting resin glue

Applications of LOM objects:

LOM objects are durable, multilayered structures which

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