rapid prototyping

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RAPID PROTOTYPING 3-D Printin g Additive Manufacturi ng Generative Manufacturi ng Process Material Deposition Manufacturi ng Layer-by- Layer Manufacturi ng Direct CAD Manufactur ing Solid Freeform Fabricat ion

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Page 1: Rapid  Prototyping

RAPID PROTOTYPING3-D

Printing

AdditiveManufacturin

g

GenerativeManufacturin

gProcess

MaterialDeposition

Manufacturing

Layer-by-Layer

Manufacturing

Direct CADManufacturi

ngSolid

FreeformFabricatio

n

Page 2: Rapid  Prototyping

WHAT and WHY ?

RAPID PROTOTYPING is a process of manufacturing

directly from the CAD data by adding material layer-by-layer without human intervention

Complexity RestraintsRelease Point for

ToolsMultiple

parts bonded into

one complex

part

Design Freedom

Affordable Customiz

ationEncouragi

ng Innovatio

n

Page 3: Rapid  Prototyping

Benefits of RAPID PROTOTYPING

Improved Product

Quality and Design

Improved Confidentiali

tyBetter

Communication

Reduced Developme

nt Costs

Shortened Product

Development Cycle

Page 4: Rapid  Prototyping

Steps

Pre Processing

• Input• Slicing

Processing

• Photo Curing• Cutting & Glueing/Joining• Melting and Solidifying

• Sealing• Polishing• PaintingPost

Processing

Page 5: Rapid  Prototyping

CLASSIFICATION

Laminated Object Manufacturing (LOM)

Fused Deposition Modelling (FDM)

Multi-Jet Modelling (MJM)

Solid Creation System (SCS)

SolidBased Selective

Laser Sintering (SLS)3 Dimensional Printing (3DP)Electron Beam Melting (EBM)

Powder

Based Stereolithography Apparatus (SLA)

Solid Ground Curing (SGC)

Liquid

Based

Page 6: Rapid  Prototyping

Laminated Object Manufacturing (LOM)

• Developed by the California-based Helisys Inc. (now Cubic Technologies)

• Uses the cutting and glueing method

Page 7: Rapid  Prototyping

FUSED DEPOSITION MODELLING (FDM)

• Developed by Stratasys

• Uses the fusing and solidifying method

• Durable, Cost-effective products with accuracies similar to stereolithography

• Longer building time

Page 8: Rapid  Prototyping

SELECTIVE LASER SINTERING (SLS)

• Uses the fusing and solidifying method

• More material options, like thermoplastic, metal powder, ceramics, etc.

• Comparatively inaccurate, rough surface and lesser detail

Page 9: Rapid  Prototyping

STEREOLITHOGRAPHY APPARATUS (SLA)

• Uses photo-curing method to solidify liquid resins using UV light.

• Limited material options and colors

• Very accurate, smooth parts are produced

Page 10: Rapid  Prototyping

MATERIALS

Factors :• Application• Function• Geometry• Post-processing

Page 11: Rapid  Prototyping

PHOTOPOLYMERS

Liquid resins which are cured and hardened with ultraviolet (UV) energy.

Photo-curable materials range in colours, opacities and rigidities.

Manufacturing processes: Stereolithography (SL) and PolyJet

Page 12: Rapid  Prototyping

POWDERED PLASTICS

Powdered nylons are “sintered”, layer by layer via a laser to form dense plastic designs

Properties : heat deflection, high strength and excellent elongation properties

Capable of more complex designs, since they don’t require any support

Page 13: Rapid  Prototyping

METALS

The powdered metals are heated and fused by a powerful Yb-fibre laser, whose energy essentially welds designs layer by layer

Requires highly trained build engineers and post-processing team

Complex, dense parts that consolidate old designs into one fluid build

Page 14: Rapid  Prototyping

THERMOPLASTICS

High performance, engineering-grade materials which exhibit many of the same properties of injection molded plastics

Examples: Polycarbonate (PC), acrylonitrile butadiene styrene (ABS), acrylonitrile styrene acrylate (ASA), etc.

Manufacturing Process:Fused Deposition Modelling (FDM)

Page 15: Rapid  Prototyping

RAPID PROTOTYPINGTHEN & NOW

Page 16: Rapid  Prototyping

19841st 3D Printer developed by Charles Hull,Named “Stereolithography Apparatus”

1996‘Genisys’ from Stratasys‘Actua 2100’ from 3D Systems‘Z402’ from Z Corporation

2008Connex500 by Objet GeometriesCould print in multiple materials simultaneously

Page 17: Rapid  Prototyping

SPECIFICATIONS

Build Area Extruders Filament Width Print Speed Horizontal (XY) Resolution Vertical (Z) Resolution

Page 18: Rapid  Prototyping

APPLICATIONSBEYOND PROTOTYPING

Page 19: Rapid  Prototyping
Page 20: Rapid  Prototyping

CONCLUSION

3D printing has been behind the scenes for decades, providing functional prototype and production parts in hundreds of industries. It will continue to benefit as methods and materials improve.

We must remember that additive manufacturing technology is not a replacement for conventional processes, rather an aid.With growing popularity of 3-D printing, there is a concern over the legalities and ethical ramifications. Little or no laws governing the field Digital files run a risk of being stolen/hacked

Page 21: Rapid  Prototyping

PRESENTED BY –

ABHISHEK GORAIBATCH: 2012-2016NATIONAL INSTITUTE OF TECHNOLOGY, DURGAPURWEST BENGAL, INDIA