unit i introduction
DESCRIPTION
About rapid prototypingTRANSCRIPT
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INTRODUCTION
RAPID
PROTOTYPING
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OUTLINE Basics of Rapid Prototyping(RP),
Need for RP system,
Classication of RP system,
!"ndamental fa#rication Process,
Basic Process of RP system,
Impacts of RP and its tooling in
Prod"ct $e%elopment process,
Benets of RP system,
&pplications of RP systems,
$igital and 'irt"al Prototyping
o"rnals
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PRODUCTDEVELOPMENT
PROCESS
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PROTOT*PE
Prototype is the frst or originalexample o something that hasbeen or will be copied or
developed ; it is a model orpreliminary version.
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&+PECT+ O! PROTOT*PE
Implementation o prototype rom the
entire product or system.
The orm o the prototype ; rom a
virtual prototype to a physical
prototype.
The degree o the approximation o the
prototype, rom a very rough
representation to an exact application
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R&PI$ PROTOT*PIN
Rapid prototyping technologies are able to
produce physical model in a layer by layer
manner directly rom their !" models
without any tools, dies and fxtures andalso with little human intervention.
RP is capable to abricate parts #uic$ly
with too complex shape easily ascompared to traditional manuacturing
technology.
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-.* PROTOT*PE+
NEE$ O! R&PI$
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NEE$ O! R&PI$PROTOT*PIN
%nable to explore the problems, ! potential oundation to developing the
system,
%arly detection o errors,
"ecrease the costly mista$es and
development time,
Increase o possible orm, ft, unction tests,
Increasing complexity,
It gives excellent visual aids or
communicating.
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I/PORT&NT NEE$ O! RP
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CL&++I!IC&TION O! RP+*+TE/+
Li0"id #ased RP systems,
+olid #ased RP systems,
Po1der #ased RP systems.
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LI2UI$ B&+E$ RP +*+TE/+
+tereolit3ograp3y &pparat"s
(+TL),
&olid 'round uring (&'),
&olid creation system (&&),
Rapid !ree4e Prototyping (R!P),
&olid *b+ect ltraviolet-aser Printer
(&*P).
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LI2UI$ B&+E$ RP +*+TE/+
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+OLI$ B&+E$ RP +*+TE/+ Laminated O#5ect /an"fact"ring (LO/),
!"sed $eposition /odeling (!$/),
Paper aminated Technology (PT),
/ulti-0et /odeling &ystem (/0/),
/elted %xtrusion /odeling (/%/).
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PO-$ER B&+E$ RP +*+TE/+
+electi%e Laser +intering (+L+),
$irect /etal Laser +intering
($/L+),
T3ree $imensional Printing,
Laser Engineered Net +3aping,
Electron Beam /elting Process,
"irect &hell Production asting.
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PO-$ER B&+E$ RP +*+TE/+
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!UN$&/ENT&L !&BRIC&TIONPROCE++
+"#tracti%e
&dditi%e
!ormati%e
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+UBTR&CTI'E
In a subtractive process, one starts with
a single bloc$ o solid material larger
than the fnal si1e o the desired ob+ect
and portion o the material are removed
until.
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&$$ITI'E
!n additive process is the exact reverse
in that the end product is much larger
than the material when it started ,
materials are manipulated so that they
are successively combined to orm it into
the desired shape.
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!OR/&TI'E
The ormative process is one where
mechanical orces or restricting orms
are applied on a material so as to orm it
into the desired shape.
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Build
Prototype
B&+IC PROCE++ O! RP
Three stages: pre-processing, building,and
post processing
RP Process Post ProcessPre Process
Generate
.STL file
Build Supports
if needed
Slicing
Remove
Supports
Clean Surface
Post Cure if needed
Part Completed
CAD Model
Surface/Solid
Model
in RP
systems
in CAD
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C&$ /O$EL CRE&TION 2irst, the ob+ect to be built is modeled using a
omputer-!ided "esign (!") sotware pac$age.
&olid modelers, such as Pro3%4'I4%%R, tend to
represent 5-" ob+ects more accurately than
wire-rame modelers such as !uto!", and will
thereore yield better results.
This process is identical or all o the RP build
techni#ues.
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CON'ER+ION TO +TL !OR/&T
To establish consistency, the &T
(stereolithography, the frst RP techni#ue)
ormat has been adopted as the standard o
the rapid prototyping industry.
The second step, thereore, is to convert the
!" fle into &T ormat. This ormat
represents a three-dimensional surace as an
assembly o planar triangles.
&T fles use planar elements, they cannot
represent curved suraces exactly. Increasing
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CON'ER+ION TO +TL !OR/&T
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CON'ER+ION TO +TL !OR/&T
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&"to $es6
6.2ile menu-save copy !s
7.&elect &T rom the types drop down
5.hec$ options-choose high(or #uality
surace) 8.lic$ save.
C&TI&
6.&elect &T command
7./aximum seg to 9.96:mm 5.&elect the model, then select yes
8.&elect %xport, o$.
CON'ER+ION TO +TL !OR/&T
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+LICE T.E +TL !ILE
In the third step, a pre-processing program
prepares the &T fle to be built.
The pre-processing sotware slices the &T
model into a number o layers rom 9.96 mm
to 9. mm thic$, depending on the build
techni#ue.
The program may also generate an auxiliarystructure to support the model during the
build. &upports are useul or delicate
eatures such as overhangs, internal cavities,
+LICE T.E +TL !ILE
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+LICE T.E +TL !ILE
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L&*ER B* L&*ER CON+TRUCTION
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L&*ER B* L&*ER CON+TRUCTION
The ourth step is the actual construction
o the part.
RP machines build one layer at a time
rom polymers, paper, or powdered metal.
/ost machines are airly autonomous,
needing little human intervention.
L&*ER B* L&*ER CON+TRUCTION
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L&*ER B* L&*ER CON+TRUCTION
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CLEAN AND FINISH
The fnal step is post-processing. Thisinvolves removing the prototype rom the
machine and detaching any supports.
&ome photosensitive materials need to be
ully cured beore use
Prototypes may also re#uire minor cleaning
and surace treatment.
&anding, sealing, and3or painting the model
will improve its appearance and durability.
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CLEAN AND FINISH
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IMPACT OF RAPID PROTOTYPING AND TOOLING IN
PRODUCT DEVELOPMENT
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CONT,..
Time saving (!" < !%) In Rapid Prototyping the di=erent design and
manuacturing activities are carried out
conc"rrently. &o there is a possible to
compress the over all product development
time
It can greatly reduce the TI/%-T*-/!R>%T
Reducing the part count and thereby
reducing assembly.
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CONT,..
The product designers can increase partcomplexity with little signifcant e=ects on
lead time and cost.
The manuacturer can reduce the labour
content o machining3casting.
It can greatly reduce material waste, waste
disposal cost.
The main savings are in costs.
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BENEFITS OF RP
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DIRECT BENEFITS
!OR PRO$UCT $E+INER+
6.an increase the part complexity with littlesignifcant e=ects.
7.an reduce the part count.
5./inimi1ing the time consume to discussionand evaluation o manuacturingpossibilities.
!OR TOOL &N$ /&NU!&CTURIN ENINEER+
6.The main savings are cost
7.an minimi1e design and manuacturing andverifcation o tooling.
5.an reduce the part count and thereorereducing assembly.
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INDIRECT BENEFITS
FOR MARKETING 1.It greatly reduces the TIME-TO-MARKET
2.Can easily expand distribution and quickly
enter foreign markets.
FOR CONSUMERS
1.The customers can buy products which meet
more closely individual needs and wants.
2.Consumer can buy products at lower prices.
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APPLICATIONS
Aerospace Automotive
Biomedical
Jewelry
Coin
Tableware
Consumer Electronics
Architecture
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AEROSPACE (8.2%)
AUTOMOTIVE(317%)
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AUTOMOTIVE (31.7%)
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BIOMEDICAL (8.8%)
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CONSUMER PRODUCTS (18.4%)
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ACADEMIC (8.6%)
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ARCHITECTURE
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DIGITAL PROTOTYPING
The digital prototyping gives virtual explore to a
complete product before it built, for conceptual
design, engineering, manufacturing, sales and
marketing departments. DP use to design, iterate, optimize, validate and
visualize their products.
It creates photorealistic rendering and animations
of products prior to manufacturing.
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CONT,.
Digital prototyping goes beyond simply creating
product design in 3D.
For product development team
1.It gives a way to access to operation of moving
parts, to determine the product will fail or not.
2.Also we can see how the various product
components interact with subsystems.
3.It reduces the number of physical prototype
thereby reducing cost and time.
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VIRTUAL PROTOTYPING
It is the technique in the process of product
development.
Virtual prototyping involves CAD/CAE software to
validate a design before committing to make a
physical prototype.
A virtual prototype intended to producing an initial
concept of design.
The virtual prototype predict the performance prior
to constructing physical prototype.
VIRTUALPROTOTYPING
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VIRTUAL PROTOTYPING
Using VP ability to explore a wide range of design
alternative leads to improvements in performance and
design quality. (Mechanical motion, assembly and
matting etc,..
Using VP time to market gets reduced sustainly
because the VP much faster than physical prototype.
JOURNALS
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JOURNALS
Rapid Prototyping Journal – Emerald insight
International Journal of Rapid Manufacturing –
Inderscience Publisher
Virtual and Physical Prototyping – Taylor and Francis
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