RAPID PROTOTYPING SERVICE MODEL

BY THE CDIO*)

EDUCATIONAL

Poznan 11. – 12.10.2010

BY THE CDIO*)

EDUCATIONAL

FRAMEWORK

*) Conceive Design Implement Operate

Lauri Tenhunen

Seppo Aarnio

RPS

CDIOINNOVATION

PROCESSES OF INDUSTRY

RPS

RP-TECHNIQUES

ELEMENTS OF RPS MODEL

(Rapid Prototyping Service Model)

WHAT IS CDIO ?

CDIO

WHAT IS CDIO ?

CDIO

AN INNOVATIVE EDUCATIONAL PROGRAM FOR PRODUCING THE NEXT GENERATION OF ENGINEERING NEXT GENERATION OF ENGINEERING LEADERS.IT FORMS THE BASIS OF YOUNG UNDERGRATUATE EDUCATION.

CDIO was developed in MIT in the late nineties

WHY CDIO ?

REAL-WORLD DEMANDS

REAL-WORLD DEMANDS

REAL-WORLD DEMANDS

ENGINEERING EDUCATION

ENGINEERING EDUCATION

ENGINEERING EDUCATION CDIOCDIO DEMANDSDEMANDSDEMANDSEDUCATIONEDUCATIONEDUCATION CDIOCDIO

” IT IS THE JOB OF ENGINEERS TO BE ABLE TO ENGINEER ”

”Graduating engineers should be able to

Conceive-Design-Implement-Operate

complex value-added engineering systems

in a modern team-based environment.”in a modern team-based environment.”

Prof Crawley, MIT

STRUCTURE OF THE CDIO SYLLABUS

Knowledge of Underlying SciencesCore Engineering

TeamworkCommunicationCommunication in Foreign Languages

Fig.1 CDIO Blocks of knowledge

Core Engineering FundamentalsAdvanced Engineering Fundamentals Engineering Reasoning and Problem Solving

Experimentation and Knowledge DiscoverySystem ThinkingPersonal Skills and AttitudesProfessional Skills and Attitudes

ESC

Fig. 2 CDIO Syllabus within the EBC and the ESC

BENEFITS OF CDIO

• Fresh ideas• Increased cooperation• Theory into praxis• Students will learn the laws and language of business world• Working together in teams with different people• Working together in teams with different people•

PRODUCT INNOVATIONS IN

INNOVATION PROCESSES OF

INDUSTRY

PRODUCT INNOVATIONS IN

ENTERPRISES

PRODUCT DEVELOPMENT CONSISTS OF SEVERAL STEPS

Fig.3 Three phases of a simplified innovation process

RAPID PROTOTYPING PERFORMANCE

RP-TECHNIQUES

RAPID PROTOTYPING PERFORMANCE

FUNDAMENTAL FABRICATION PROCESSES

19/10/2010 S.AARNIO

C K Chua, K F Leong, & C S Lim: Rapid Prototyping: Principles and Applications

AM

Fig. 4

Additive manufacturing (AM) is defined by ASTM as the process of

joining materials to make objects from

3D model data, usually layer upon

layer.layer.

RP is one form of AM. It is used in making prototypes

All RP techniques basically follow the same 5-step system:

1. Creating a 3D CAD model of the design

2. Converting the CAD model to STL format

3. Slicing the STL file into thin cross-sectional layers

4. Constructing the model one layer atop another4. Constructing the model one layer atop another

5. Cleaning and finishing the Model

To prototype successfully you need to select an appropriate technical RP tool and form an RP team.

CAD MODEL CREATION:

• using a CAD software package

• or by using a laser scanner or a Coordinate

Measuring Machine (CMM). (”Reverse

engineering””)

19/10/2010 S.AARNIO

CONVERSION TO STL FORMAT:

The standard data interface between CAD sofware and the

machine is the STL-format (Stereolithography).

An STL-file approximates the shape of a part using triangular

facets. Small facets produce a high quality surface.

19/10/2010 S.AARNIO

Since the .stl format is universal, this process is identical

for all of the RP build techniques.

SLICING THE STL FILE:

The program may also generate an auxiliary structure to

Support the model during the build

http://www.youtube.com/watch?v=80aXU5q2Kgg

19/10/2010 S.AARNIO

19/10/2010 S.AARNIO

SUPPORT MATERIAL

LAYER BY LAYER CONSTRUCTION:

The fourth step is the actual construction of the part.

Using one of several techniques (described later) RP

machines build the model layer by layer.

The material´s initial states are:

• LIQUID

19/10/2010 S.AARNIO

• LIQUID

• SOLID or

• POWDER

• Practically no limitations to the form to be produced.

• Reduction in time and cost (could range 50 – 90%. Wohler)

• Errors and flaws can be detected at an early stage.

• RP/RM can be used in different industries and fields of life

(medicine, art and architecture, marketing..)

• Discussions with the customer can start at an early stage.

• Assemblies can be made directly in one go.

• Material waste is reduced.

GENERAL ADVANTAGES OF RP

19/10/2010 S.AARNIO

• Material waste is reduced.

• No tooling is necessary.

• The designers and the machinery can be in separate places.

•

APPLICATIONS OF AM

Technology

19/10/2010 S.AARNIO

The task was to test different alternative INTAKE MANIFOLDS. The

19/10/2010 S.AARNIO

The task was to test different alternative INTAKE MANIFOLDS. The

parts (three) were made of Windform XT with laser sintering. By using

SLS the time from desktop to product took only about 10 % of the time

earlier.

19/10/2010 S.AARNIO

Wind tunnel tests

Medicine

19/10/2010 S.AARNIO

Models of skulls etc can be used for training of surgical operations

19/10/2010 S.AARNIO

Parts made of titamium are used for replacements

These siamese twins were succesfully separated. The operation was planned with models of the skulls.

19/10/2010 S.AARNIO

Architecture

19/10/2010 S.AARNIO

RP/AM-TECHNOLOGIES

• Stereolithography (SLA)• Fused Deposition Modeling (FDM)• Selective Laser Sintering (SLS)• Laminated Object Manufacturing (LOM)• 3D Printing• Direct metal laser sintering (DMLS)

19/10/2010 S.AARNIO

SLASTEREOLITHOGRAPHY

19/10/2010 S.AARNIO

http://www.youtube.com/watch?v=eJ7s-1XvDFw&feature=related

FDMFUSED DEPOSITION MODELING

19/10/2010 S.AARNIO

http://www.youtube.com/watch?v=oYLjyI5honM&feature=related

SLSSELECTIVE LASER SINTERING

19/10/2010 S.AARNIO

http://www.youtube.com/watch?v=ShX_qXSTj_E&feature=related

LOMLAMINATED OBJECT MANUFACTURING

19/10/2010 S.AARNIO

http://www.youtube.com/watch?v=Z1WNA6tdfWM&feature=related

RPS BY THE CDIO FRAMEWORKRPS BY THE CDIO FRAMEWORK

To formulate the RPS model logically, we will

first arrange the needed elements into groups

of objects (nouns) and actions (verbs) and of objects (nouns) and actions (verbs) and

then describe the three processes

simultaneously

THE LIST OF OBJECTS (NOUNS) WILL INCLUDE FOLLOWING:

• The RP team (including students and experts)

• The customer and its agents

• The target product and its properties

• The RP technique chosen

• The Prototype

• The time schedule and the budget

THE LIST OF ACTIONS (VERBS) WILL INCLUDE FOLLOWING:

• Discussing the task and choosing the innovation level

• Regulating and adjusting the RP process during work

• Changing, Developing and Iterating the Prototype

• Testing the prototype solutions

• Finishing the best prototype

• Saving the necessary CAD documents

• Consulting and Advising by experts• The time schedule and the

budget • Consulting and Advising by experts

• Learning to conceive, design, implement and operate the RP process by the students

• Making decisions by the customers

Next slide (Fig. 5) will demonstrate the three simultaneous processes.

3.

Implementing

4.

OperatingFinal

Prototype

Evaluation

Learning outcomes

Penetration

Decisions

Marketing, Production

Test marketing

Commercial iterations

Product development

FIGURE:RPS in relation to CDIO Engineering Education and Enterprise product development function

Designing

2.

Conceiving

1. Project idea

conception

Prototype

Product Design

Evalution

Planning

Planning with CAD

RP modelling

Technical iterationsProduct conception

Requirement Analysis

Fig. 5

The students involved in the RPS processare able to adopt the • techniques of RP engineering and also• fundamentals of engineering service processes and • business to business service sales.• business to business service sales.

RP team, proper for CDIO education

framework within a university, would

include:

• competent teacher(s),

• group of students, • group of students,

• programmer(s),

• enterprise representatives.

Enterprise Actions

Assignment

Idea

Conception

Team Actions

Participation

Evaluation

Product targets

Learning targets

Fig. 6

RPS Model and Actions. The model includes four elements:

The team, the system, the product and the enterprise

Enterprise Actions

Assignment

Requirements

Idea

Conception

Team Actions

Participation

Evaluation

Product targets

Learning targets

Planning

CAD models

Mentoring

CAD modelling

Evaluation

Enterprise Actions

Assignment

RequirementsRP modelling

Iterations

Evaluation

Planning

Feedback

Idea

Conception

Planning

CAD models

Team Actions

Participation

Evaluation

Product targets

Learning targets

Mentoring

CAD modelling

Evaluation

Developing physical models

RP modelling

Iterations

Enterprise Actions

Assignment

Requirements

Evaluation

Planning

Feedback

Testing:

Technical and

commercial

Proposal

Final Prototype

Idea

Conception

Planning

CAD models

Team Actions

Participation

Evaluation

Product targets

Learning targets

Mentoring

CAD modelling

Evaluation

Developing physical models

Proposal

Approval

Modifications

RP modelling

Iterations

Enterprise Actions

Assignment

Requirements

Evaluation

Planning

Feedback

Testing:

Technical and

commercial

Proposal

Final Prototype

Testing

Decisions

Final Product

Evaluation

Learning outcomes

Idea

Conception

Planning

CAD models

Team Actions

Participation

Evaluation

Product targets

Learning targets

Mentoring

CAD modelling

Evaluation

Developing physical models

Proposal

Approval

Modifications

RPS

CDIOINNOVATION

PROCESSES OF INDUSTRY

RPS

RP-TECHNIQUES

BY THE USE OF CDIO EDUCATIONAL FRAMEWORK WE CAN EDUCATE PROFESSIONAL ENGINEERS WHO ARE:

• Technically competent

• Socially aware and

• Entreprenially astute professionals,

who will become the next engineering leaders

ANY QUESTIONS ?

THANK YOU FOR YOUR ATTENTION

THANK YOU FOR YOUR ATTENTIONATTENTION

HAVE A NICE DAY

ATTENTION

HAVE A NICE DAY