Professional Documents
Culture Documents
Unit 1 ADM
Unit 1 ADM
UNIT - I
Introduction: Prototyping fundamentals, Historical development, Fundamentals of Rapid Prototyping,Advantages and Limitations of Rapid Prototyping,
Commonly used Terms, Classification of RP process,Rapid Prototyping Process Chain: Fundamental Automated Processes
UNIT - II
Liquid-based Rapid Prototyping Systems: Stereo lithography Apparatus (SLA): Models and specifications, Process, working principle, photopolymers, photo
polymerization, Layering technology, laser and laser scanning, Applications, Advantages and Disadvantages, Case studies. Solid ground curing (SGC): Models
and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies Solid-based Rapid Prototyping Systems: Laminated
Object Manufacturing (LOM): Models and specifications, Process, working principle, Applications, Advantages and Disadvantages, Case studies. Fused
Deposition Modeling (FDM): Models and specifications,Process, working principle, Applications, Advantages and Disadvantages, Case studies
UNIT - III
Powder Based Rapid Prototyping Systems: Selective laser sintering (SLS): Models and specifications,Process, working principle, Applications, Advantages
and Disadvantages, Case studies. Three dimensional Printing (3DP): Models and specifications, Process, working principle, Applications,Advantages and
Disadvantages, Case studies. Rapid Tooling: Introduction to Rapid Tooling (RT),Conventional Tooling Vs RT, Need for RT. Rapid Tooling Classification; Indirect
Rapid Tooling Methods:Spray Metal Deposition, RTV Epoxy Tools, Ceramic tools, Investment Casting, Spin Casting, Diecasting, Sand Casting, 3D Keltool
process. Direct Rapid Tooling : Direct AIM, LOM Tools, DTM RapidTool Process, EOS Direct Tool Process and Direct Metal Tooling using 3DP.
UNIT - IV
Rapid Prototyping Data Formats: STL Format, STL File Problems, Consequence of Building Valid and Invalid Tessellated Models, STL file
Repairs: Generic Solution, Other Translators, Newly Proposed Formats. Rapid Prototyping Software’s: Features of various RP software’s like
Magics, Mimics, Solid View, View Expert, 3 D View, Velocity 2, Rhino, STL View 3 Data Expert and 3 D doctor.
UNIT - V
RP Applications: Application - Material Relationship, Application in Design, Application in Engineering,Analysis and Planning, Aerospace Industry,
Automotive Industry, Jewelry Industry, Coin Industry, GIS application, Arts and Architecture. RP Medical and Bioengineering Applications: Planning
and simulation of complex surgery, Customized Implants & Prosthesis, Design and Production of Medical Devices, Forensic Science and
Anthropology, Visualization of Biomolecules.
ME711PE: COMPOSITE MATERIALS (PE – II)
.
TEXT BOOKS:
1. Rapid prototyping; Principles and Applications /Chua C.K., Leong K.F. and LIM C.S/World
Scientific Publications
2. Rapid Manufacturing /D.T. Pham and S.S. Dimov/Springer
ME711PE:Additive Manufacturing
Introduction
What is Additive Manufacturing?
• The term Rapid Prototyping (or RP) is used to describe a process for rapidly creating a system or
part representation before final release or commercialization.
• A recently formed Technical Committee within ASTM International agreed that new terminology
should be adopted. Recently adopted ASTM consensus standards now use the term Additive
Manufacturing.
• The basic principle of this technology is that a model, initially generated using a 3D Computer
Aided Design (3D CAD) system, can be fabricated directly without the need for process planning.
Introduction
Definition of a Prototype
A prototype is the first or original example of something that has been or will be
copied or developed; it is a model or preliminary version;
Prototype fundamentals
Common to all the different techniques of RP is the basic approach they adopt, which can
be described as follows:
1) A model or component is modeled on a Computer-Aided Design/Computer-Aided
Manufacturing (CAD/CAM) system.
2) The model which represents the physical part to be built must be represented as
closed surfaces which unambiguously define an enclosed volume.
3) This means that the data must specify the inside, outside and boundary of the
model. This requirement will become redundant if the modeling technique used is
solid modeling.
4) This is by virtue of the technique used, as a valid solid model will automatically be
an enclosed volume.
5) This requirement ensures that all horizontal cross sections that are essential to RP
are closed curves to create the solid object.
FUNDAMENTALS OF RAPID PROTOTYPING
Common to all the different techniques of RP is the basic approach they adopt, which can be
described as follows:
1. The solid or surface model to be built is next converted into a format dubbed the “STL”
(STereoLithography) file format which originates from 3D Systems.
2. The STL file format approximates the surfaces of the model by polygons.
3. Highly curved surfaces must employ many polygons, which means that STL files for
curved parts can be very large.
4. However, there are some rapid prototyping systems which also accept IGES (Initial
Graphics Exchange Specifications) data, provided it is of the correct “flavor”.
Rapid Prototyping Wheel
FUNDAMENTALS OF RAPID PROTOTYPING
Input
1. Input refers to the electronic information required to describe the physical object with
3D data.
2. There are two possible starting points a computer model or a physical model.
3. The computer model created by a CAD system can be either a surface model or a
solid model.
4. On the other hand, 3D data from the physical model is not at all straightforward. It
requires data acquisition through a method known as reverse engineering.
5. In reverse engineering, a wide range of equipment can be used, such as CMM
(coordinate measuring machine) or a laser digitizer, to capture data points of the
physical model and “reconstruct” it in a CAD system.
FUNDAMENTALS OF RAPID PROTOTYPING
Method
While they are currently more than 20 vendors for RP systems, the method employed by
each vendor can be generally classified into the following categories:
1. photo-curing, cutting and glueing/joining, melting and solidifying/fusing and
joining/binding.
2. Photo-curing can be further divided into categories of single
i. laser beam,
ii. double laser beams and
iii. masked lamp.
Material
The initial state of material can come in either solid, liquid or powder state. In solid state, it
can come in various forms such as pellets, wire or laminates. The current range materials
include paper, nylon, wax, resins, metals and ceramics.
RAPID PROTOTYPING
Applications
Most of the RP parts are finished or touched up before they are used for their intended
applications.
Applications can be grouped into
(1)Design
(2) Engineering, Analysis, and Planning and
(3) Tooling and Manufacturing.
A wide range of industries can benefit from RP and these include, but are not limited to,
aerospace, automotive, biomedical, consumer, electrical and electronics products.
ADVANTAGES OF RAPID PROTOTYPING
Direct Benefits
ADVANTAGES OF RAPID PROTOTYPING
Direct Benefits-Modernize cars Product completion time drastically decreased as years progress
Benefits to the Tooling and Manufacturing Engineer-The main savings are in costs.
Indirect Benefits
Benefits of marketing
• Part size
• Production series: Generally suitable for unitary or small series and is not relevant
for mass production. For small sized parts, series up to 25000 parts/year are
already possible.
Limitations of AM
• The densities of 99.9% can be reached, there can be some residual internal
porosities.
• Mechanical properties are usually superior to cast parts but in general inferior to
wrought parts.
COMMONLY USED TERMS
As is illustrated in the RP Wheel in Figure 1.3, three methods are possible under the
“Photo-curing” method. The single laser beam method is most widely used and include
all the above RP systems with the exception of (2), (11), (13) and (14).
Cubital (2) and Light Sculpting (11) use the masked lamp method,
Two laser beam method is still not commercialized. Rapid Freeze (13) involves the
freezing of water droplets and deposit in a manner much like FDM to create the
prototype.
Solid-Based
Solid-Based
(7) CAM-LEM’s CL 100
(8) Ennex Corporation’s Offset Fabbers
Referring to the RP Wheel in Figure 1.3, two methods are possible for solid-based
RP systems. RP systems (1), (3), (4) and (9) belong to the Cutting and
All the above RP systems employ the Joining/Binding method. The method
of joining/binding differs for the above systems in that some employ a laser
while others use a binder/glue to achieve the joining effect.
RAPID PROTOTYPING PROCESS CHAIN
Subtractive fabrication processes: Include most forms of machining processes — CNC or otherwise. These include
milling, turning, drilling, planning, sawing, grinding, EDM, laser cutting, water-
Additive/Rapid prototyping processes: such as Stereolithography and Selective Laser Sintering fall into the additive
fabrication processes category.
formative: fabrication processes are: Bending, forging, electromagnetic forming and plastic injection molding.
Process Chain
Additive Manufacturing Process chain
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
• Once the STL file has been created, it can be sent directly to the target AM
machine.
• Ideally, it should be possible to press a “print” button and the machine should build
• the part straight away.
• However there may be a number of actions required prior to building the part.
• The first task would be to verify that the part is correct.
• AM system software normally has a visualization tool that allows the user to view
and manipulate the part.
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
• The user may wish to reposition the part or even change the orientation to allow it
to be built at a specific location within the machine.
• Normally, an incorrect setup procedure will still result in a part being built.
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
Step 5: Build Setup
• The first few stages of the AM process are semi-automated tasks that may
require considerable manual control, interaction, and decision making.
• Once these steps are completed, the process switches to the computer-
controlled building phase.
• All AM machines will have a similar sequence of layer control, using a height
adjustable platform, material deposition, and layer cross-section formation.
• All machines will repeat the process until either the build is complete or there is
no source material remaining.
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
Step 6: Removal and Cleanup
• More often the parts still require a significant amount of manual finishing before
they are ready for use.
• The part must be either separated from a build platform on which the part was
produced or removed from excess build material surrounding the part.
• Some AM processes use additional material other than that used to make the
part itself (secondary support materials).
Additive Manufacturing Process chain
Step 7: Post Process
• Post-processing refers to the (usually manual) stages of finishing the parts for
application purposes.
• This may involve abrasive finishing, like polishing and sandpapering, or
application of coatings.
Additive Manufacturing Process chain
The Eight Steps in Additive Manufacture
Step 8: Application
• Some AM processes create parts with small voids or bubbles trapped inside
them, which could be the source for part failure under mechanical stress.
• Some processes may cause the material to degrade during build or for materials
not to bond, link, or crystallize in an optimum way.