Rapid Prototyping

PE4652 – Teknologi Manufaktur
Rapid Prototyping and Rapid Tooling
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Structure of the lecture
1 Introduction
2 RP and RT in product development
3 Economic aspects
4 Overview about systems and technologies
5 Examples of application
6 Future and perspectives
7 Conclusions
TEKNIK DAN SISTEM PRODUKSI

Why is Rapid Prototyping Important?
Problem :
▪ Reduction of product development time forced by
innovation pressure and market competition
▪ Increase of product complexity
▪ Despite of Virtual Reality tools need for physical
models
▪ Time-consuming conventional, often also manual,
model making
Solution :
▪ Development of techniques for generative
production of prototypes directly from CAD-data
▪ Mobilizing of adjacent time and cost advantages

Rapid Prototyping and Rapid Tooling – definitions
Rapid Prototyping (RP) – Generative (layer-by-layer) build up of
parts directly from CAD-data
– Usually no molds or tools required
– Accessing of high economic potentials
while producing complex geometries in
small batches
Rapid Tooling (RT) – Same principles and characteristics as

for Rapid Prototyping
– Layer-by-layer build up of molds and
dies (direct RT)
– Shaping of molds and dies from RP-
made master patterns (indirect RT)

1 Introduction
3 Economic aspects
7 Conclusions

Key factor (Time to Market) – 1
Product development time
– Boundary conditions during product development process:

• Non-concrete or quickly changing customer’s demands
• Growing importance of design and individualization
• Environmental aspects
• Decreasing product lifetime
• Falling prices and cost pressure
• Law-enforced boundaries and standards
– Often more than 25% of product development time are spent for
manufacture of prototypes and models
– Delays in market maturity lead to over-proportional profit
reduction compared to other cost factors

Key factor (Time to Market) – 2
Costs
– Most of the later costs
are defined in a very
early stage of product
development cycle
Conclusion
– Models, prototypes and
patterns have to be
available in a very short
time to guarantee a
successful product

Needs for prototypes during product development

Use of RP models by branches
– Consumer products and

automotive are taking more
than 50% of RP-models
produced
– Increasing trend in medical
areas
– others: sporting goods, non
military marine use, ...
Source: Wohlers Associates Inc., 2002

Use of RP models by application

1 Introduction
3 Economic aspects
7 Conclusions

RP-/RT-system installations worldwide

Worldwide revenues of RP-/RT-branch

Ranking of the most important RP-/RT-systems
SL MJM LOM 3DP

(3D Systems (3D Systems) (Helisys SLS (Z Corp.)
et al.) et al.) (EOS, 3D
FDM ModelMaker Genisys
(Stratasys) (Solidscape) Systems (Stratasys)
et al.)

Economic of Rapid Prototyping :
Machine Cost Response Material Application
Time
Fused Deposition $10/hr 2 weeks ABS or Casting Strong Parts
Modeler 1600 Wax Casting Patterns
(FDM)
Laminated Object $18/hr 1 week Paper (wood- Larger Parts
Manufacturing like) Concept Models
(LOM)
Sanders Model $3.30/hr 5 weeks Wax Casting Pattern
Maker 2 (Jet)
Selective Laser $44/hr 1 week Polycarbonate light: 100%;
Sintering 2000 TrueForm margin: 0">Casting
(SLS) SandForm Patterns
Concept Models
Stereolithography $33/hr 2 weeks Epoxy Resin Thin walls

250 (SLA) (Translucent) Durable Models
Z402 3-D Modeller $27.50/hr 1 week Starch/Wax Concept Models
(Jet)

1 Introduction
3 Economic aspects
7 Conclusions

Rapid Prototyping (RP)
A family of fabrication processes developed to make

engineering prototypes in minimum lead time based on a
CAD model of the item
• RP allows a part to be made in hours or days, given that
a computer model of the part has been generated on a
CAD system

RP – Two Basic Categories:
1. Material removal RP (RT) - machining, using a
dedicated CNC machine that is available to the design
department on short notice
– Starting material is often wax
• Easy to machine
• Can be melted and resolidified
– The CNC machines are often small - called desktop
machining
2. Material addition RP - adds layers of material one at a

time to build the solid part from bottom to top

Starting Materials in Material Addition RP
Liquid monomers that are cured layer

by layer into solid polymers
Powders that are aggregated and

bonded layer by layer
Solid sheets that are laminated to

create the solid part

Rapid Prototyping Systems
All RP techniques employ the same basic five-step process.
1. Create a CAD model of the design
2. Convert the CAD model to STL format (stereolithography)
3. Slice the STL file into thin cross-sectional layers
4. Construct the model one layer atop another
5. Clean and finish the model

Solid Model to Layers
Figure 34.1. Conversion of a solid model of an object into

layers (only one layer is shown).

More About Rapid Prototyping
• Alternative names for RP:

– Layer manufacturing
– Direct CAD manufacturing
– Solid freeform fabrication
– Rapid prototyping and manufacturing (RPM)
– Additive manufacturing
• RP technologies are being used increasingly to

make production parts and production tooling,
not just prototypes

Classification of RP Technologies
• There are various ways to classify the RP
techniques that have currently been developed
• The RP classification used here is based on the
form of the starting material:
1. Liquid-based
2. Solid-based
3. Powder-based

Liquid-Based Rapid Prototyping Systems
• Starting material is a liquid

• About a dozen RP technologies are in this
category
• Includes the following processes:
– Stereolithography
– Solid ground curing
– Droplet deposition manufacturing

Stereolithography (STL)
RP process for fabricating a solid plastic part out of

a photosensitive liquid polymer using a directed
laser beam to solidify the polymer
• Part fabrication is accomplished as a series of layers -
each layer is added onto the previous layer to gradually
build the 3-D geometry
• The first addition RP technology - introduced 1988 by 3D
Systems Inc. based on the work of Charles Hull
• More installations than any other RP method

Stereolithography
Figure 34.2 Stereolithography: (1) at the start of the process, in which

the initial layer is added to the platform; and (2) after several layers
have been added so that the part geometry gradually takes form.

Figure 34.3 A part produced by stereolithography (photo courtesy of 3D Systems, Inc.).

STL

Facts about STL
• Each layer is 0.076 mm to 0.50 mm (0.003 in to

0.020 in.) thick
– Thinner layers provide better resolution and more
intricate shapes; but processing time is longer
• Starting materials are liquid monomers
• Polymerization occurs on exposure to UV light
produced by laser scanning beam
– Scanning speeds ~ 500 to 2500 mm/s

Part Build Time in STL
Time to complete a single layer :
Ai
Ti = + Td
vD
where
Ti = time to complete layer i;
Ai = area of layer i;
v = average scanning speed of the laser beam at the surface;
D = diameter of the “spot size,” assumed circular;
Td = delay time between layers to reposition the worktable

Part Build Time in STL - continued
Once the Ti values have been determined for all
layers, then the build cycle time is:
ni
Tc =  Ti
i =1
where
Tc = STL build cycle time;
ni = number of layers used to approximate the part
▪ Time to build a part ranges from one hour for small parts of
simple geometry up to several dozen hours for complex parts

Solid Ground Curing (SGC)
Like stereolithography, SGC works by curing a

photosensitive polymer layer by layer to create
a solid model based on CAD geometric data
• Instead of using a scanning laser beam to cure a
given layer, the entire layer is exposed to a UV
source through a mask above the liquid polymer
• Hardening takes 2 to 3 s for each layer

Solid Ground Curing
Figure 34.4 SGC steps
for each layer:
(1) mask preparation,
(2) applying liquid
photopolymer layer,
(3) mask positioning
and exposure of
layer,
(4) uncured polymer
removed from
surface,
(5) wax filling,
(6) milling for flatness
and thickness.

SGC

Facts about SGC
• Sequence for each layer takes about 90 seconds

• Time to produce a part by SGC is claimed to be about
eight times faster than other RP systems
• The solid cubic form created in SGC consists of solid
polymer and wax
• The wax provides support for fragile and overhanging
features of the part during fabrication, but can be
melted away later to leave the free-standing part

Droplet Deposition Manufacturing (DDM)
Starting material is melted and small droplets are

shot by a nozzle onto previously formed layer
• Droplets cold weld to surface to form a new

layer
• Deposition for each layer controlled by a moving
x-y nozzle whose path is based on a cross
section of a CAD geometric model that is sliced
into layers
• Work materials include wax and thermoplastics

Solid-Based Rapid Prototyping Systems
• Starting material is a solid

• Solid-based RP systems include the
following processes:
– Laminated object manufacturing
– Fused deposition modeling

Laminated Object Manufacturing (LOM)
Solid physical model made by stacking layers of sheet

stock, each an outline of the cross-sectional shape of a
CAD model that is sliced into layers
• Starting sheet stock includes paper, plastic, cellulose,

metals, or fiber-reinforced materials
• The sheet is usually supplied with adhesive backing
as rolls that are spooled between two reels
• After cutting, excess material in the layer remains in
place to support the part during building

Laminated Object Manufacturing
Figure 34.5 Laminated object manufacturing.

LOM

Fused Deposition Modeling (FDM)
RP process in which a long filament of wax or polymer is

extruded onto existing part surface from a workhead to
complete each new layer
• Workhead is controlled in the x-y plane during each layer

and then moves up by a distance equal to one layer in
the z-direction
• Extrudate is solidified and cold welded to the cooler part
surface in about 0.1 s
• Part is fabricated from the base up, using a layer-by-
layer procedure

FDM

Multi-Jet Modeling (MJM)
Process principle
– Layer-by-layer
deposition of molten
plastic droplets using a
line of piezoelectric ink
jets
Characteristics
– Designed as 3D-
network-printer for
concept models
Materials
– Thermopolymer based
on Paraffin

Powder-Based RP Systems
• Starting material is a powder

• Powder-based RP systems include the following:
– Selective laser sintering
– Three dimensional printing

Selective Laser Sintering (SLS, DMLS)
Moving laser beam sinters heat-fusible powders in

areas corresponding to the CAD geometry model
one layer at a time to build the solid part
• After each layer is completed, a new layer of loose

powders is spread across the surface
• Layer by layer, the powders are gradually bonded
by the laser beam into a solid mass that forms the
3-D part geometry
• In areas not sintered, the powders are loose and
can be poured out of completed part

SLS

Three Dimensional Printing (3DP)
Part is built layer-by-layer using an ink-jet printer to

eject adhesive bonding material onto successive
layers of powders
• Binder is deposited in areas corresponding to the
cross sections of part, as determined by slicing the
CAD geometric model into layers
• The binder holds the powders together to form
the solid part, while the unbonded powders
remain loose to be removed later
• To further strengthen the part, a sintering step
can be applied to bond the individual powders

Three Dimensional Printing
Figure 34.6 Three dimensional printing: (1) powder layer is

deposited, (2) ink-jet printing of areas that will become the part,
and (3) piston is lowered for next layer (key: v = motion).

3D-Printing

1 Introduction
3 Economic aspects
7 Conclusions

RP Types :

RP Applications
• Applications of rapid prototyping can be

classified into three categories:
1. Design
2. Engineering analysis and planning
3. Tooling and manufacturing

Design Applications
• Designers are able to confirm their design by

building a real physical model in minimum time
using RP
• Design benefits of RP:
– Reduced lead times to produce prototypes
– Improved ability to visualize part geometry
– Early detection of design errors
– Increased capability to compute mass properties

Engineering Analysis and Planning
• Existence of part allows certain engineering

analysis and planning activities to be
accomplished that would be more difficult
without the physical entity
– Comparison of different shapes and styles to
determine aesthetic appeal
– Wind tunnel testing of streamline shapes
– Stress analysis of physical model
– Fabrication of pre-production parts for process
planning and tool design

Tooling Applications
• Called rapid tool making (RTM) when RP is

used to fabricate production tooling
• Two approaches for tool-making:
1. Indirect RTM method
2. Direct RTM method

Indirect RTM Method
Pattern is created by RP and the pattern is used to

fabricate the tool
• Examples:
– Patterns for sand casting and investment casting
– Electrodes for EDM

Direct RTM Method
RP is used to make the tool itself

• Example:
– 3DP to create a die of metal powders followed by
sintering and infiltration to complete the die

Rapid Tooling

Manufacturing Applications
• Small batches of plastic parts that could not be

economically molded by injection molding
because of the high mold cost
• Parts with intricate internal geometries that could
not be made using conventional technologies
without assembly
• One-of-a-kind parts such as bone replacements
that must be made to correct size for each user

Problems with Rapid Prototyping
• Part accuracy:
– Staircase appearance for a sloping part surface due to
layering
– Shrinkage and distortion of RP parts
• Limited variety of materials in RP

– Mechanical performance of the fabricated parts is
limited by the materials that must be used in the RP
process

1 Introduction
3 Economic aspects
7 Conclusions

Trends and perspectives Tendencies for Rapid Prototyping
technologies
– »Personal Modelers«
– 3D-printers for concept models
– Rapid Prototyping for complex models with high
demands regarding materials
– Rapid Tooling
– Rapid Manufacturing
3D-Printing
– Reduction of purchasing and running costs
3DP-Model of a pump station – Systems improvent
• Accuracy
• Handling
• Materials, mechanical properties
• Speed
– Decentralized use in the various development
departments of a company
Source: 4DConcepts

Trends and perspectives Rapid Tooling
– Improvement of systems
– Increase of tool lifetime
– Comparability of molding parameters to
serial steel tools
– »Conformal cooling«
– Graduated build up of tools with changing
properties
Rapid Manufacturing
– Use of RT-technologies for end product
production
– Small series production (racing, aerospace,
executive/special products, ...)
– »Mass Customization«
– Establish beneath/instead of conventional
production methods
Source: 4DConcepts

1 Introduction
3 Economic aspects
7 Conclusions

Conclusions
Product development
– Main goal: reduction of»Time to Market«
– Manufacture of models, samples and
prototypes using RP/RT opens cost and
time savings
– Requirements to models depend on
product development phase
Rapid Prototyping/Rapid Tooling

– Layer-by-layer generative build up of parts –
Production of a model or a tool
– Selection of a technology regarding required
properties, stiffness, materials, batch number,
...
– Future developments gain to optimization of
handling, closeness to serial products,
production of final products

Rapid Prototyping

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PE4652 – Teknologi Manufaktur

Rapid Prototyping and Rapid Tooling

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Rapid Tooling (RT) – Same principles and characteristics as

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

– Boundary conditions during product development process:

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

– Consumer products and

Source: Wohlers Associates Inc., 2002

TEKNIK DAN SISTEM PRODUKSI

Source: Wohlers Associates Inc., 2002

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Source: Wohlers Associates Inc., 2002

TEKNIK DAN SISTEM PRODUKSI

Source: Wohlers Associates Inc., 2002

TEKNIK DAN SISTEM PRODUKSI

SL MJM LOM 3DP

TEKNIK DAN SISTEM PRODUKSI

Stereolithography $33/hr 2 weeks Epoxy Resin Thin walls

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

A family of fabrication processes developed to make

TEKNIK DAN SISTEM PRODUKSI

2. Material addition RP - adds layers of material one at a

TEKNIK DAN SISTEM PRODUKSI

Liquid monomers that are cured layer

Powders that are aggregated and

Solid sheets that are laminated to

TEKNIK DAN SISTEM PRODUKSI

All RP techniques employ the same basic five-step process.

1. Create a CAD model of the design

2. Convert the CAD model to STL format (stereolithography)

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

4. Construct the model one layer atop another

5. Clean and finish the model

TEKNIK DAN SISTEM PRODUKSI

Figure 34.1. Conversion of a solid model of an object into

TEKNIK DAN SISTEM PRODUKSI

• Alternative names for RP:

• RP technologies are being used increasingly to

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

• Starting material is a liquid

TEKNIK DAN SISTEM PRODUKSI

RP process for fabricating a solid plastic part out of

TEKNIK DAN SISTEM PRODUKSI

Figure 34.2 Stereolithography: (1) at the start of the process, in which

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

• Each layer is 0.076 mm to 0.50 mm (0.003 in to

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

Like stereolithography, SGC works by curing a

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

TEKNIK DAN SISTEM PRODUKSI

• Sequence for each layer takes about 90 seconds