WHAT IS RAPID PROTOTYPING ?


 Rapid prototyping enables the quick
fabrication of physical models using three
dimensional computer aided design (CAD)
data. Used in a wide range of industries, rapid
prototyping allows companies to turn
innovative ideas into successful end products
rapidly and efficiently.
 SUBTRACTIVE PROCESS

Remove material from a solid work piece and the
result is the final part. There are the example of
the process :
 Carving
 Drilling
 Milling
 Turning
 Grinding
Base material :
 Wood
 Metal
 Aluminium
 ADDITIVE PROCESS

The part is constructed directly from a digital 3D
model created through Computer Aided Design
(CAD) software. The part made layer by layer.
Each layer is a cross section of the part derived
from a 3D model .
Base material :
 Metal
 Iron powder
 Aluminium
 CAD
Idea
PROGRAM
Part
drawing

CAM
PROGRAM

NC
program

CNC Finished
part
MACHINE

Flow process of additive process

 HISTORY OF FUSED DEPOSITION
MODELLING (FDM)


 Fused Deposition Modelling (FDM) was developed by S. Scott
Crump in the late 1980s and was commercialized in 199 by
Stratasys.

 With the expiration of the patent on this technology there is now

a large open-source development community, as well as
commercial and DIY variants, which utilize this type of 3D printer.

 This has led to a two orders of magnitude price drop since this
technology’s creation.

 This commonly used for modeling, prototyping and production

applications.
 PROCESS

 The model or part is produced by extruding small
beads of thermoplastic material to form layers as the
material hardens immediately after extrusion from
the nozzle.

 A plastic filament or metal wire is unwound from a

coil and supplies material to an extrusion nozzle
which can turn the flow on and off.

 The thermoplastics are heated past their glass

transition temperature and are then deposited by an
extrusion head.
 The nozzle can be moved in both horizontal and
vertical directions by a numerically controlled
mechanism.


 The nozzle follows a tool-path controlled by a
computer-aided manufacturing (CAM) software
package, and the part is built from the bottom
up, one layer at a time.

 Stepper motors or servo motors are typically

employed to move the extrusion head.

 FDM generally has some restrictions on the

slope of the overhang, and cannot produce
unsupported stalactites
FDM PROCESS

BASE MATERIAL

 Thermoplastic
 Glass transition
 Polycarbonate
 Polyamides
 Polystyrene
 Lignin
 Casting wax
 Elastomer
 Polyester
 HISTORY OF STEREOLITHOGRAPHY


 More recently, attempts have been made to
construct mathematical models of the
stereolithography process and
design algorithms to determine whether a
proposed object may be constructed by the
process
 Base material
 Protogen White

 Protogen White is suited for general purpose applications with ABS-like specifications and ideal for
markets that demand accurate RTV patterns, durable concept models, highly accurate parts.

 Xtreme

 Xtreme is a resin with good all round properties including a high impact strength, a high elongation
at break and excellent surface quality. Xtreme is ideal for tough enclosures, snap fit assemblies and
replacing CNC machined parts.

 NanoTool

 NanoTool produces strong, stiff, high temperature resistant parts, suited for wind tunnel tests for
aerospace and automotive applications. It exhibits superior sidewall quality, along with excellent
detail resolution which makes it for instance ideal for metal plating purposes.

 WaterClear

 WaterClear material is suitable for prototype parts that require fully neutral transparency.
 Flow process


The Stereolithography process begins with the conversion of customer 3D CAD Data into an STL
file. Proprietary software is used to slice the model into a series of fine layers, with support
structures added as necessary. The STL file is then sent to print on the Stereolithography machine.

 Using a UV laser bream the first cross section of the STL file is traced out onto a platform, placed
within the vat of photo-curable resin - the resin cures/hardens as it comes into contact with the
laser.

 Once the first layer has been completed the platform is lowered by 0.05 – 0.15mm (dependent on
build mode selected) with a fresh layer of resin covering the build surface.

 The next layer is then traced out, curing and bonding the resin to the layer below.

 The stereolithography process repeats layer by layer until the model and any support structures
are “fully grown” in the resin. Once complete the platform is raised, allowing excess resin to drain
away before the model is removed from the platform.

 SLA technicians then wash the SLA model and remove any supporting structures, prior to
completing any customer specified finishing or painting.
 SELECTIVE LASER SINTERING


 - Developed and patented by DR. Carl Deckard
and DR. Joe Beaman at University of Texas at
Austin in the mid- 1980.

- They were involved in the resulting start up

company DTM, established to design and build
the SLS machines.
 BASE MATERIAL

- Use single component powder, such direct
metal laser sintering.

- Powder are commonly produced by ball milling.

- Most SLS machines use 2 component powders

ex : -Coated powder
-Powder mixture
 FLOW PROCESS

 - In single-component powder, laser melts only the
outer surface of the particles.

- SLS produce part from relative wide of

commercially available powder materials.
ex: polymers such as nylon.

- SLS use around the world due easily make

complex geometries direct from digital CAD data.

- SLS as a way build a prototype parts in the design

cycle.
 History of ballistic

 The mysteries of gunpowder and its tremendous force attracted
such scientists as Leonardo da Vinci, Galileo, and Isaac Newton.
Firearms operate faster than the human eye can see, and so
these early researchers tried to determine the flight of
projectiles.


 The study of ballistics has found a variety of uses. For example,
cartridge-actuated devices such as aircraft ejection seats use
propellants. Ballistics also played a part in the development of
automobile air bags, life rafts, and other containers that can be
inflated with propellant gas. (See also ammunition; artillery;
guided missile; rocket.)

 FLOW PROCESS

 The BPM personal modeller came with all hardware and
software enclosed in one compact unit.

 The bpm utilized ink jet or droplet based manufacturing

techniques, it builds the models by firing micro droplets of
molten wax material from a moving nozzle or jet onto a
stationary platform, the platform then lowers and the process
is repeated for each layer of the model

 The part can be scaled, rotated or translated to a desired

orientation. This is performed on a 5 axis workstation
 HISTORY OF (LOM)

 (LOM) system was shipped in 1991

 was developed by Helisys of Torrance, CA

 The main components of the system are a

feed mechanism that advances a sheet over a
build platform
 BASE MATERIAL OF (LOM)

 Paper

 Plastic

 Metal laminated

 Knife

 Laser cutter
 FLOW PROCESS LOM

 Sheet is adhered to a substrate with a heated roller.

 Laser traces desired dimensions of prototype.

 Laser cross hatches non-part area to facilitate waste removal.

 Platform with completed layer moves down out of the way.

 Fresh sheet of material is rolled into position.

 Platform moves up into position to receive next layer.

 The process is repeated.
 ADVANTAGES

 1. Simple file format
 2. Create impossible shapes and cutting
 3. Print in color
 4. Working mechanisms
 5. Reduced waste
 6. Complement visualization
 Different Between Rapid
Prototyping and Rapid Tooling

RAPID PROTOTYPING RAPID TOOLING

Faster and less expensively Expensive cost and production

massive

Prototypes can be used for Produce a mold quickly

design testing

Automatically construct physical More faster and more less

model from (CAD) data expensively then rapid
prototyping

Done using 3D printing Latest moldmaking technologies