RAPID PROTOTYPING

ASHISH MENON- 13BME0317

SUMIT SANKHYAN- 13BME0051
SARKAR- 13BME0281

SIDDHARTHA

What Is Rapid Prototyping?

Rapid Prototyping (RP) can be defined as a group of

techniques used to quickly fabricate a scale model of a

part or assembly using three-dimensional computer aided
design (CAD) data.
RP process belong to the generative (or additive)
production processes in which form is shaped by material
removal or plastic deformation.
The part is fabricated by deposition of layers contoured in
a (x-y) plane two dimensionally. The third dimension (z)
results from single layers being stacked up on top of each
other, but not as a continuous z-coordinate. Therefore, the
prototypes are very exact on the x-y plane but have stairstepping effect in z-direction.

Why use RP?

The reasons of Rapid Prototyping are
To increase effective communication.
To decrease development time.
To decrease costly mistakes.
To minimize sustaining engineering changes.
To extend product lifetime by adding necessary features and eliminating
redundant features early in the design.
Increasing variety of options in the product.
Decreasing delivery times.

Growth of RP in 10 years

Stereolithography
SLA is the most commonly used rapid prototyping technique.
There are many different ways to 3D print an object. But nearly all of them utilize

computer aided design (CAD) files.

CAD files are digitalized representations of an object. They're used by engineers and
manufacturers to turn ideas into computerized models that can be digitally tested,
improved and most recently, 3D printed.
In 3D printing or additive manufacturing CAD files must be translated into a
"language," or file type, that 3D printing machines can understand. Standard Tessellation
Language (STL) is one such file type and is the language most commonly used for
stereolithography, as well as other additive manufacturing processes.
Since additive manufacturing works by adding one layer of material on top of another,
CAD models must be broken up into layers before being printed in three dimensions.
STL files "cut up" CAD models, giving the 3D printing machine the information it needs to
print each layer of an object.

 Unlike the desktop printer you use to print documents, SLA machines don't

extrude ink or some other liquid onto a surface. Instead an SLA machine starts
with an excess of liquid plastic, some of which is cured, or hardened, to form a
solid object.
SLAs have four main parts: a tank that can be filled with liquid plastic

(photopolymer), a perforated platform that is lowered into the tank, an ultraviolet

(UV) laser and a computer controlling the platform and the laser. In the initial
step of the SLA process, a thin layer of photopolymer (usually between 0.05-0.15
mm) is exposed above the perforated platform. The UV laser hits the perforated
platform, "painting" the pattern of the object being printed.
The UV-curable liquid hardens instantly when the UV laser touches it, forming

the first layer of the 3D-printed object. Once the initial layer of the object has
hardened, the platform is lowered, exposing a new surface layer of liquid
polymer. The laser again traces a cross section of the object being printed, which
instantly bonds to the hardened section beneath it.

This process is repeated again and again until the entire object has been formed

and is fully submerged in the tank. The platform is then raised to expose a threedimensional object. After it is rinsed with a liquid solvent to free it of excess resin,
the object is baked in an ultraviolet oven to further cure the plastic.

Merits and Demerits

Stereolithography is an ideal solution for creating prototypes because it

creates highly accurate, durable objects fairly quickly and relatively

inexpensively. SLA machines can even create oddly shaped objects, which
can be difficult to produce using traditional prototyping methods.
Many industries from medical to manufacturing use stereolithography
to build prototypes and, on occasion, final products. A car manufacturer, for
example, might use stereolithography to create a prototype casting of a car
door handle. Such a prototype can be tested for fit and form and, once
perfected, can serve as the master pattern for a machined auto part.
On negative side working with liquid can be messy. Also some parts
require post curing operation in separate oven apparatus which can lead to
unnecessary delay and losses.

Stereolithography Animation

3D Printing
3D printing is a form of additive manufacturing technology where

a three dimensional object is created by laying down successive

layers of material. It is also known as rapid prototyping, is a
mechanized method whereby 3D objects are quickly made on a
reasonably sized machine connected to a computer containing
blueprints for the object.
The 3D printing concept of custom manufacturing is exciting to
nearly everyone. This revolutionary method for creating 3D
models with the use of inkjet technology saves time and cost by
eliminating the need to design; print and glue together separate
model parts. Now, you can create a complete model in a single
process using 3D printing.
The basic principles include materials cartridges, flexibility of
output, and translation of code into a visible pattern.

History of 3D Printing
The technology for printing physical 3D objects from digital data was first developed

by Charles Hull in 1984. He named the technique as Stereo lithography and

obtained a patent for the technique in 1986. While Stereo lithography systems had
become popular by the end of 1980s, other similar technologies such as Fused
Deposition Modelling (FDM) and Selective Laser Sintering (SLS) were introduced.
In 1993, Massachusetts Institute of Technology (MIT) patented another technology,
named "3 Dimensional Printing techniques", which is similar to the inkjet technology
used in 2D Printers. In 1996, three major products, "Genisys" from Stratasys, "Actua
2100" from 3D Systems and "Z402" from Z Corporation, were introduced.
In 2005, Z Corp. launched a breakthrough product, named Spectrum Z510, which
was the first high definition color 3D Printer in the market. Another breakthrough in
3D Printing occurred in 2006 with the initiation of an open source project, named
Reprap, which was aimed at developing a selfreplicating 3D printer.

Manufacturing a model with the 3D printer

The model to be manufactured is built

up a layer at a time. A layer of powder

is automatically deposited in the model
tray. The print head then applies resin
in the shape of the model. The layer
dries solid almost immediately. The
model tray then moves down the
distance of a layer and another layer
of power is deposited in position, in the
model tray. The print head again
applies resin in the shape of the
model, binding it to the first layer. This
sequence occurs one layer at a time
until the model is complete

3D Printing Capabilities
As anticipated, this modern technology has smoothed the path for numerous new possibilities in
various fields. The list below details the advantages of 3D printing in certain fields.
1. Product formation is currently the main use of 3D printing technology. These machines allow
designers and engineers to test out ideas for dimensional products cheaply before committing to
expensive tooling and manufacturing processes.
2. In Medical Field, Surgeons are using 3d printing machines to print body parts for reference before
complex surgeries. Other machines are used to construct bone grafts for patients who have suffered
traumatic injuries. Looking further in the future, research is underway as scientists are working on
creating replacement organs.
3. Architects need to create mockups of their designs. 3D printing allows them to come up with these
mockups in a short period of time and with a higher degree of accuracy.
4. 3D printing allows artists to create objects that would be incredibly difficult, costly, or time intensive
using traditional processes.

3D Printing Limitations
A point often overlooked is that the labour cost that remains. Counter to common

perception, 3D printing does not happen at the touch of a button; it involves

considerable pre- and post-processing, which incur non-trivial labour costs. The
starting point for any 3D printing process is a 3D file that can be printed. Just
having an electronic CAD drawing is not sufficient; currently, there is no way to
automatically convert the CAD drawing into a 3D file.
Following the printing, the parts produced have to be recovered, cleaned, washed
and inspected. This, in turn, means that using 3D printing for the aftermarket
services an application where it makes a lot of sense requires making a
significant upfront investment in generating the printable files of the spare parts
that would likely be needed. This investment would have to outweigh the cost of
keeping a lifetime supply of spare parts in inventory, which is a tough call for small
bolts, brackets, and connectors that make up the bulk of aftermarket demand.

Selective laser sintering

An additive manufacturing (AM) technique that uses a laser as the power source

to sinter powdered material, aiming the laser automatically at points in space

defined by a 3D model, binding the material together to create a solid structure.
SLS is a relatively new technology that so far has mainly been used for rapid
prototyping and for low-volume production of component parts. Production roles
are expanding as the commercialization of the technology improves.
The laser selectively fuses powdered material by scanning cross-sections
generated from a 3-D digital description of the part (for example from a CAD file)
on the surface of a powder bed. After each cross-section is scanned, the powder
bed is lowered by one layer thickness, a new layer of material is applied on top,
and the process is repeated until the part is completed.
Because finished part density depends on peak laser power, rather than laser
duration, a SLS machine typically uses a pulsed laser. The SLS machine
preheats the bulk powder material in the powder bed somewhat below its melting
point, to make it easier for the laser to raise the temperature of the selected
regions the rest of the way to the melting point.

Technology
SLS does not need a separate feeder for support material because the part being

constructed is surrounded by unsintered powder at all times which allows for the
construction of previously impossible geometries.
Since the machine's chamber is always filled with powder material the fabrication of

multiple parts has a far lower impact on the overall difficulty and price of the design.
Through a technique known as 'Nesting, multiple parts can be positioned to fit within

the boundaries of the machine. One design aspect which should be observed
however is that with SLS it is 'impossible' to fabricate a hollow but fully enclosed
element. This is because the unsintered powder within the element can't be drained.

 Thermoplastic powder is spread by a roller on the surface of a build cylinder. The cylinder

piston moves down one object layer thickness to accommodate the new layer of powder.
In the powder delivery system, a piston moves upwards to supply a measured quantity of
powder for each layer.
A laser beam is then traced over the surface of the compacted powder to selectively melt and
bond it, to form an object layer.
The chamber is maintained at a temperature below the melting point of the powder, so that the
laser heat only elevates the temperature needed for sintering. This speeds up the process.
This process is repeated layer-by-layer until the whole object is fabricated.

 After the object is fully formed, the piston is raised to elevate it. Excess powder is

brushed away, and final finishing may be done manually.

No supports are required in this method, since overhangs and undercuts are

supported by the solid powder bed.

SLS offers the key advantage of making functional parts in essentially final

materials. This system is mechanically more complex than other technologies.

Materials and Applications

SLS can produce parts from a relatively wide range of commercially available powder

materials. These include polymers such as nylon or polystyrene, metals

including steel, titanium, alloy mixtures, and composites and green sand.
The physical process can be full melting, partial melting, or liquid-phase sintering.

Depending on the material, up to 100% density can be achieved with material

properties comparable to those from conventional manufacturing methods. In many
cases large numbers of parts can be packed within the powder bed, allowing very high
productivity.
SLS technology is gaining use around the world due to its ability to easily make very

complex geometries directly from digital CAD data. While it began as a way to
build prototype parts early in the design cycle, it is increasingly being used in limitedrun manufacturing to produce end-use parts.

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