RAPID PROTOTYPING (RP)

CAD/CAM/CAE
 RAPID PROTOTYPING (RP)

• Prototyping is one of the step to finalize a product design.

• A prototype is an original working model of the product, and can be

called as the first stage of manufacturing.

• It helps in conceptualization of a design.

• Before start of production a prototype is usually fabricated and tested.

• Manual prototyping by a skilled craftsman has been an age old

practice for many centuries.

 RAPID PROTOTYPING (RP)

• Second phase of prototyping started around mid-1970s,when a soft

prototype modeled by 3D curves and surfaces could be

• stressed in virtual environment,

• simulated and

• tested with exact material and other properties.

• Third and the latest trend of prototyping, i.e., Rapid Prototyping (RP)

is layer-by-layer material deposition.

• The historical development of RP and related technologies is
presented in table
 RAPID PROTOTYPING (RP)
WHAT IS RP
• Rapid Prototyping (RP) is also known as “Toolless Model Making”,
“Solid Freeform Fabrication”, “Generative Manufacturing”, “Layered
Manufacturing”, “Desk-top manufacturing”, “Computer automated
manufacturing" etc.

• The first technique for rapid prototyping became available in the late
1980s and was used to produce models and prototype parts.

• Rapid prototyping is the automatic construction of physical objects

using solid free form fabrication at a lower cost.

• RP enable components to be made without the need for conventional

tooling in the first instance or indeed without the need to engage the
services of skilled model-makers.
 RAPID PROTOTYPING (RP)
DEFINITIONS OF RP

• 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.

• Rapid prototyping (RP) is a family of fabrication methods to

make engineering prototypes in minimum possible lead times
based on a computer-aided design (CAD) model of the item.
 RAPID PROTOTYPING (RP)
MATERIAL

• Some techniques use two materials in the course of

constructing parts.
• The first material is the part material and the second is the
support material (to support overhanging features during
construction).
• The support material is later removed by heat or dissolved
away with a solvent or water.
 RAPID PROTOTYPING (RP)
MATERIAL

• In some cases, the RP part can be the final part, but typically
the RP material is not strong or accurate enough.

• When the RP material is suitable, highly convoluted shapes

(including parts nested within parts) can be produced because
of the nature of RP.
 RAPID PROTOTYPING (RP)
USE OF RP
 RAPID PROTOTYPING (RP)

CATEGORIES OF MANUFACTURING PROCESSES

RAPID PROTOTYPING (RP)
Standard Triangle Language
 RAPID PROTOTYPING (RP)
SURFACE FINISH
• In all commercial RP processes, 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 stair-stepping effect in z-direction.

• If model is deposited with very fine layers,

i.e., smaller z-stepping, model looks like original.
RAPID PROTOTYPING (RP)
 RAPID PROTOTYPING (RP)
WHY RAPID

• Neither RAPID nor PROTOTYPE

• Construction of a model with traditional methods take from

several hours to several days, depending on the method used
and the size and complexity of the model.
• RP needs hours ranging from 2 to 72.
• RP can typically produce models in a few hours, although it can
vary widely depend on the type of machine being used and the
size and number of models being produced simultaneously.
 RAPID PROTOTYPING (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.
 RAPID PROTOTYPING (RP)
• Rapid Prototyping decreases development time by allowing
corrections to a product to be made early in the process.
• By giving engineering, manufacturing, marketing, and
purchasing a look at the product early in the design process,
mistakes can be corrected and changes can be made while
they are still inexpensive.
• The trends in manufacturing industries continue to emphasize
the following:
• Increasing number of variants of products.
• Increasing product complexity.
• Decreasing delivery time.

• Rapid Prototyping improves product development by enabling

better communication in a concurrent engineering environment.
 RAPID PROTOTYPING (RP)
CONCURRENT ENGINEERING (Simultaneous E) Parallel E
• Methodology of reconstructing product development activity by
using cross functional team approach.
• Improves efficiency of product design.
• Reduced product development cycle.
• CE brings people from several function department in design & mfg.
• Representative from each department develops the product as a team.
• Everyone interact from start and perform their task in parallel.
• Team reviews the design from each function point of view.
• Vendor development department is also included.
• Any bottleneck is thoroughly studied and rectified.
• Each department start processing parallel.
• Procurement of material, tools, m/cry, training.- delay causing.
• Opportunity to marketing and other dept. to review design- mfg.
• Needs intensive team work.
• Reduce lead time.
 RAPID PROTOTYPING (RP)
Conventional product design approach
 RAPID PROTOTYPING (RP)
APPLICATIONS

Rapid prototyping has the following applications.

• In the field of making patterns and mould and dies for casting
and injection mouldings.
• In electronic and automotive sector.
• In medical industry to develop medical devices and
instruments.
• In aerospace field for satellites, spacecraft, aircraft, planes,
interior of a airplane cockpit etc.
 RAPID PROTOTYPING (RP)

Useful Conditions for RP

• Single unique item or small number of copies needed

• Shape of object is in computer form

• Shape is too complex to be economically generated using

conventional methods
• Reduction in prototyping times (from weeks to days)
• Reduction in prototyping costs
• Increase of the possible design iterations (from 2-3 to 8-9)
• RP machines are still expensive and material cost is also more.

• RP parts are not comparable to CNC machined parts in surface finish,

dimensional accuracy , strength, elasticity, reflective index etc.
RAPID PROTOTYPING (RP)
 RAPID PROTOTYPING (RP)
METHODOLOGY OF RAPID PROTOTYPING

•Basic methodology in current RP techniques follows:

• A CAD model is first constructed

• It is then converted to STL format. The resolution can be set to
minimize stair stepping.
• RP machine processes .STL file by creating sliced layers of the model.
• The first layer of the physical model is created.
• The model is then lowered by the thickness of the next layer.
• Additional layers are bonded on the top of the first shaped according
to their respective cross sectional planes.
• This process is repeated until the prototype is complete.
• The model and any supports are removed.
• The surface of the model is then finished and cleaned.
 RAPID PROTOTYPING (RP)
RP systems

• A survey in 1999 identified some 40 different RP manufacturing

approaches.

• Some of these are well established “main stream” RP systems

while others are more recent arrivals with much to prove.

• Also included in the list are systems that are still at the
development stage and may not become commercially
available, feasible RP systems.
 RAPID PROTOTYPING (RP)
RP Processes
• RP processes can be classified into three types:
• Liquid based
• The initial material is resin, which solidify under light.
• STL (Steriolithography)
• Solid based
• Material is solid: wire, roll or laminate
• FDM (Fused Deposited Modeling) , LOM (Laminated Object Manufacturing)
• Powder based
• Powder is used as input.
• SLS (Selective Laser Sintering) 3D Printing
3DP three-dimensional printing
3DWM three-dimensional welding and milling
BPM ballistical particle manufacture
CAM-LEM computer aided manufacturing-laminated engineering materials
CC contour crafting
CLOM curved laminated object manufacturing
DLF direct light fabrication
DLMS direct laser metal sintering
ECLD-SFF electrochemical liquid deposition for solid freeform fabrication
EDSSM extrusion and deposition of semi-solid metals
EFF extrusion freeforming
EPDFF electrophotographic powder deposition for freeform fabrication
FDC fused deposition of ceramics
FDM fused deposition modelling
FDMet fused deposition of metals
FFF fast freeform fabrication
FI fast inkjet
GMAW gas metal arc welding
LCRHLS local chemical reaction heat by laser scanning
LCVD laser chemical vapour deposition
LDM laser diode manufacturing
LENS laser engineered net shape
LM layered manufacture
LML laser microchemical lathe
LOM laminated object manufacturing
M2SLS multimaterial selective laser sintering
Meso SDM mesoscopic shape deposition manufacturing
Mold SDM mold shape deposition manufacturing
PLD pulsed laser deposition
PPD pointwise powder deposition
RFP rapid freeze prototyping
RBC robocasting
RPBPS rapid pattern based powder sintering
RSLA refrigerative stereolithography
SALD selective area laser deposition
SADVI selective area laser deposition and vapour infiltration
SGC solid ground curing
SLA stereolithography
SLPR selective laser powder remelting
SLS selective laser sintering
TIF temperature induced forming
TLP thick layer prototyping
WFDM wirefeed direct metals
 STEREOLITHOGRAPHY (SLA)
• Stereolithography was the first RP process made
commercially available in 1988.
• SLA was developed by 3D Systems of Valencia, CA, USA.
• The company was founded in 1986, and since then, a number
of different RP techniques have become available.
• It builds models layer by layer by Ultra Violet laser scanning of
a photo reactive resin.
• Resin gets cured (polymerized) when impinged by UV laser.
• On completion of all layers, the object is placed in a UV curing
chamber to ensure complete solidification.
• Automotive, aerospace, electronics and medical sector use
SLA as rapid & inexpensive method of producing prototypes.
 STEREOLITHOGRAPHY (SLA)
• A SL machine consists of a build platform, which is mounted in
a vat of resin and a UV Helium-Cadmium or Argon ion laser.
• The laser scans the first layer and platform is then lowered
equal to one slice thickness and left for short time (dip-delay)
so that liquid polymer settles to a flat and even surface and
prevent bubble formation.
• The new slice is then scanned.
• Schematic diagram of a typical Stereolithography apparatus is
shown in figure.
• Once the complete part is deposited, it is removed from the vat
and then excess resin is drained.
• It may take long time due to high viscosity of liquid resin.
• The green part is then post-cured in an UV oven after
removing support structures.
 STEREOLITHOGRAPHY (SLA)

• In this process photosensitive liquid resin which forms a solid

polymer when exposed to ultraviolet light is used as a

fundamental concept.

• Due to the absorption and scattering of beam, the reaction only

takes place near the surface and voxels of solid polymeric

resin are formed.

 STEREOLITHOGRAPHY (SLA)

• Blade spreads resin on the part as the blade traverses the vat.

• This ensures smoother surface and reduced recoating time.

• It also reduces trapped volumes which are sometimes formed

due to excessive polymerization at the ends of the slices.

• This would otherwise result in an island of liquid resin having

thickness more than slice thickness is formed.

STEREOLITHOGRAPHY (SLA)
STEREOLITHOGRAPHY (SLA)
 STEREOLITHOGRAPHY (SLA)

Highlights of Stereolithography

• The first Rapid Prototyping technique and still the most widely
used.
• Inexpensive compared to other techniques.
• Uses a light-sensitive liquid polymer.
• Requires post-curing since laser is not of high enough power
to completely cure.
• Parts are quite brittle and have a sticky surface.
• Accuracy in z can suffer.
• Support structures are typically required.
• Process is simple: There are no milling or masking steps
required.
• Uncured material can be toxic. Ventilation is a must.
STEREOLITHOGRAPHY (SLA)
 STEREOLITHOGRAPHY (SLA)
Summary of the SLA process

Materials available : Epoxy-based photocurable resins

Minimum laser beam : 0.2 mm

Layer thickness : 0.05 - 0.25 mm

Finishing available : Models can be lightly sanded and sprayed with

standard non-water based paints

Tooling methods available : Vacuum casting, reaction injection moulding,

direct injection mould tooling, metal spray
tooling, investment casting
 STEREOLITHOGRAPHY (SLA)
The sequence of steps for producing an Stereolithography layer is shown:
 STEREO LITHOGRAPHY (SLA)
• Its advantages are that
• it is well proven technique,
• requires no attention
• high dimensional accuracy and
• best surface finish
• Complex geometry, easily obtained

• Some of the disadvantages are that

• the technique requires support structure,
• the components can get warped
• the resin is expensive
• can be hazardous to the environment.
• The initial cost of the process is high and
• it requires long time to heat and to cool down.