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Rapid Prototyping
Rapid Prototyping
Sridhar.S.Jetty
History of RP systems
It started in 1980’s
First technique is Stereolithography (SLA)
It was developed by 3D systems of Valencia in California, USA in 1986.
Fused deposition modelling (FDM) developed by stratasys company in 1988.
Laminated object manufacturing (LOM) developed by Helisis (USA).
Solid ground Curing developed by Cubitol corporation of Israel.
Selective laser sintering developed by DTM of Austin, Texas (USA) in 1989.
Sanders Model maker developed by Wilton incorporation USA in 1990.
Multi Jet Modelling by 3D systems.
3-D Printing by Solygen incorporation, MIT, USA.
Rapid Tooling
Rapid Manufacturing
Automotive RP Services
Biomedical Applications – I
Prosthetic parts
Presurgical planning models
3D visualization for education and training
Biomedical Applications – II
Customized surgical implants
Mechanical bone replicas
Anthropology
Forensics
Architecture
3D visualization of design space
Iterations of shape
Sectioned models
Fashion & Jewelry
Shoe Design
Jewelry
Pattern for lost wax
Other castings
These examples highlight just a few of the developments in RP and some of the new and exciting applications.
This information, coupled with research into ongoing developments, illustrates several interesting trends.
RP for the production of finished manufactured parts. Bell Helicopter is using RP to produce metal castings for
its helicopters. Technikon Free State of Bloemfontein, South Africa, is using laser sintering to manufacture a
device used at fitness centers to measure blood pressure, body fat, and weight. A user of the FDM Titan
machine from Stratasys produced a replacement pulley in polycarbonate for an industrial belt sander.
Growing demand in the medical industry. Andy Christensen of Medical Modeling LLC of Golden, Colorado,
USA, said the demand for RP models in the medical industry has doubled over the past 2-3 years. Yet, he
believes that 90 to 95 percent of the market remains untapped. Already, orthodontics company Align
Technology of Santa Clara, California, has produced more than 1 million RP models using its stereolithography
machines. Align is purchasing up to 50 SLA 7000 machines for use with its Invisalign system, a process of
producing invisible plastic aligners for straightening adult teeth. Separately, Interpore Cross International, a
medical device company, is using seven ModelMaker machines from Solidscape to manufacture spinal
implants.
Color. Z Corp. is leading the way, and others are sure to follow. Color can be used to distinguish parts in
complex assemblies. It can also be used to make the exterior housing of a product, such as a cellular phone, look
similar to the finished product, complete with colored buttons and other features.
Material advancements. New materials, such as WaterClear, are enabling companies to create models,
prototypes, and series production parts that were before expensive or impractical to build. With some RP
materials approaching the aesthetic and functional qualities of popular injection-molded thermoplastics,
companies can push the limits to levels unheard of not long ago.
Micro parts. With computers and hand held electronic devices shrinking, the appetite for small parts grows.
RP’s style of building parts in layers, coupled with lasers, makes it possible to produce very small parts and
Perhaps the most promising trend is that all of these applications may become more affordable. Recent
developments have yielded RP systems that are significantly lower in price. This is true even in technologies
that produce parts in photopolymers. Objet Geometries Ltd. of Rehovot, Israel, is using 1536 jets to deposit and
harden photopolymer, layer by layer. Another company is hard at work developing an alternative method of
quickly and accurately depositing and hardening photopolymer in a way that may surprise many.
Classification of RP systems.
Stereolithography
Stereolithography (SL) is one of several methods used to create 3D-printed objects. It's the process by which a
uniquely designed 3D printing machine, called a stereolithograph apparatus (SLA) converts liquid plastic into
solid objects.
Stereolithography is a laser-based technology that uses a UV-sensitive liquid resin. A UV laser beam scans the
surface of the resin and selectively hardens the material corresponding to a cross section of the product, building
the 3D part from the bottom to the top. The required supports for overhangs and cavities are automatically
generated, and later manually removed.
It is the first RP system developed by 3D SYSTEMS of Valencia in California, USA in 1986.
First Model developed was 250/50 followed by 250/30, 3500, 5000 and 7000.
SLA is a laser based Rapid Prototyping process which builds parts directly from CAD by curing or
hardening a photosensitive resin with a relatively low power laser.
In this process photosensitive liquid resin which forms a solid polymer when exposed to ultraviolet light is
used as a fundamental concept. Due to the absorption and scattering of beam, the reaction only takes place
near the surface and voxels of solid polymeric resin are formed. A SL machine consists of a build platform
(substrate), which is mounted in a vat of resin and a UV Helium-Cadmium or Argon ion laser. The laser
In new SL systems, a blade spreads resin on the part as the blade traverses the vat. This ensures smoother
surface and reduced recoating time. It also reduces trapped volumes which are sometimes formed due to
excessive polymerization at the ends of the slices and an island of liquid resin having thickness more than
slice thickness is formed (Pham and Demov, 2001). Once the complete part is deposited, it is removed from
the vat and then excess resin is drained. It may take long time due to high viscosity of liquid resin. The
green part is then post-cured in an UV oven after removing support structures.
Build strategies have been developed to increase build speed and to decrease amount of
resin by depositing the parts with a higher proportion of hollow volume. These
strategies are devised as these models are used for making cavities for precision castings. Here
walls are designed hollow connected by rod-type bridging elements and skin is introduced that
close the model at the top and the bottom. These models require openings to drain out uncured
resin.
Process Parameters:
Laser Type: Helium Cadmium Laser (He-Cd)
Laser Power: 24mW
Laser Life: 2000 hours
Re-coat material: Zaphir
Minimum Slice Thickness: 0.1mm
Beam Diameter: 0.2mm
Scan Speed: 0.75m/sec
Maximum Part Volume: 0.25x0.25x0.25 m
Maximum Part Weight: 9 kgs
SOFTWARE USED
SLA CONTROL AND SET UP SOFTWARE: It operates on SLA 250 and SLA 500
machines. It has got three packages.
a) SLA VIEW: UNIX based system for viewing and positioning.
b) BRIDGE WORKS: UNIX based software for generating support structures.
The final .STL FILE one which supports in addition to original file are then sliced into
horizontal cross sections and saved as slice file.
The slice files are then masked to create four separate files that control SLA machine ending
with 5 extensions L, R, V and
Important one is V file. I.e. Vector file. The V file contains actual line data that the laser
will follow to cure the shape of the part.
R file is the range file which contains data for solid or open fields as well as re-coater
blade parameters.
The four build files are downloaded to SLA which begins building supports with platen
adjust above the surface level. The first few support layers are actually cured into
perforations into platen, thus providing a solid anchor for the rest of the part.
By building, SLA uses laser to scan the cross section and fill across the surface of resin
which is cured or hardened into the cross sectional shape. The platen is lowered as the
slices are completed so that more resin is available in the upper surface of the part to be
cured. Final step is Post Processing.
Applications
Investment Casting.
Wind Tunnel Modeling.
Tooling.
Injection Mould Tools
UNIT 2:
Principle of Operation
The sinter station has build piston at the center and feed piston on the either side. The
model is built layer by layer like other rapid prototyping process so that the build piston
will begin at the top of its range and will lower in increments of the set layer size as parts
are built.
With the build piston at the top a thin layer of powder is spread across the build area by
the roller from one of the feed piston. The laser then cures in a raster sweeps motion
across the area of the parts being built.
The part piston lowers and more powder is deposited and the process is continued until
all of the part is built.
The build media is removed from the machine. It is a cake of powder.
This cake is taken to the breakout station where excess powder is removed from the part
manually with brushes
The excess powder that has been removed can be kept for recycling and can be reused.
Some material needs additional finishing. Some of the finishing techniques include grid
blasting, sanding, polishing, drilling, taping and coating
Applications:
1. As conceptual models.
2. Functional prototypes.
3. As Pattern masters.
First, a part model is created in a STL file with AutoCad or another design program..
• The model needs to be imported into Stratasys’ software, Insight.
• The software slices the .stl file into horizontal layers mathematically, generating the required
supports.
• Insight creates tool paths required for the extrusion head.
• The system draws cross-sectional layers one at a time in the X, Y, and Z coordinate by using a
heated material extrusion process.
Import the .stl file of part model into Stratasys’ software, Insight, which slices the model into
horizontal layers.
• The supports are created if they are needed and the tool paths for the extrusion head are
planned.
• ABS material feeds into the temperature-controlled FDM extrusion head, where it is heated to a
semi-liquid state.
• The head extrudes and deposits the material in 0.254mm layers onto a fixtureless base, one
layer at a time in X and Y coordinates first.
• When the layer is finished, the head moves in Z direction to the next layer.
• Each layer is extruded with precision, and the layers are bonded and solidified.
• The designed object becomes a solid three-dimensional part.
Complex geometries and cavities that would otherwise be problematic become practical
with FDM technology
FDM APPLICATIONS
FDM Thermoplastics
FDM Technology uses the same tried and tested thermoplastics found in traditional
manufacturing processes. For applications that demand tight tolerances, toughness and
environmental stability – or specialized properties like electrostatic dissipation, translucence,
biocompatibility, VO flammability or FST ratings – there’s an FDM thermoplastic that can
deliver.
FDM 3D Printers
Idea Series
Develop your ideas with affordable models and prototypes. Idea Series 3D Printers fit your
desktop and your budget.
Design Series
Perfect your designs with strong, durable and dimensionally-stable parts that withstand tough
testing.
Production Series
Bring agility and aesthetics to every stage of product development with the widest range of
colors and material properties for prototypes and tooling.
Aerospace
Automotive
Commercial
Consumer
Industrial
Medical
Constructional Details :
ADVANTAGES:
Ideal technology for short production runs .
Volume of the production environment is as big as what we get from Stereo lithography.
Dimensional accuracy is good .
DISADVANTAGES :
Apart from the advantages it has also some disadvantages such as when the liquid polymer
solidifies these some wax also gets entrapped in the artifact.
Process:
The steps in process are as follows
First a CAD model of the part is created and it is sliced in to layers using cubitos data
front end software.
STEPS IN SGC
At the beginning of a layer creation step the flat work surface is sprayed with
photosensitive resin.
2. Development of photomask
3. Expose photomask
The photomask is positioned over the work surface a powerful UV lamp hardens the exposed
photosensitive resin.
Once all layers are completed the wax is removed and any
finishing operations such as sanding etc can be performed no
post curing is necessary.
APPLICATIONS OF SGC
fabricating wax patterns for investment casting
Fused Deposition: Solid Ground Curing Ink Jet:
Tooling & casting
Medical imaging
Laminated object manufacturing: 1 Foil supply. 2 Heated roller. 3 Laser beam. 4. Scanning prism. 5
Laser unit. 6 Layers. 7 Moving platform. 8 Waste.
Laminated object manufacturing (LOM) is a rapid prototyping system developed by Helisys Inc.
(Cubic Technologies is now the successor organization of Helisys) In it, layers of adhesive-
coated paper, plastic, or metal laminates are successively glued together and cut to shape with a
knife or laser cutter. Objects printed with this technique may be additionally modified by machining or
drilling after printing. Typical layer resolution for this process is defined by the material feedstock and
usually ranges in thickness from one to a few sheets of copy paper.[1]
The process is performed as follows:
LOM MATERIALS:
plastic, or
metal laminates are successively glued together and cut to shape with a knife or laser cutter.
This technology is very versatile as almost any material can be glued. The more common
material used is paper as it is easily cut. Plastic can also be used, using a blade or a laser
during the cutting stage. Metallic sheets are more unusual because the cutting stage is
more complicated.
Process details
This is a very simple process making it easy to use, cheap and fast. The printing precision
depends on the layer thickness and thus depends on the material. Compared to other
technologies, it is not considered as very precise. The withdrawal of the support parallelepipoids
is an exhausting and critical task that can lead to damaged objects.
APPLICATIIONS OF LOM
Form/fit testing,
Less detailed parts,
Rapid tooling patterns
LOM machines are used mainly for rapid proptotyping plastic parts. Its low price and
fastness makes it convenient to make prototypes, even though the produced objects are
far from end-use parts.
Mcor proposes a particular kind of LOM that they named Selective Deposition
Lamination (SDL). It is a paper based technology that adds color in the print. Sheets of
paper are colour printed, selectively glued and cut with a blade. The glue is only applied
in the surface corresponding to the object, then it is easier to excavate the final object.
Plus, the addition of colour allows this technology to compete with binder
jettingtechnologies to produce multicolor objects, even if the quality is not the same.
MCor allows multicolor 3D prototyping, Binder Jetting does the same for production. If
you are interested in 3D printing a multicolor object, download your model !
Conceptual modelers offer abundant op- portunities for making solid business im- provements
and have great untapped poten- tial for cutting time-to-market. In the eyes of many, conceptual
The first layer is sprayed directly onto a platen by a row of presicely controlled jets that can
produce points 0.08mm square. This layer is then machined by a hot roller to a thickness of
0.08mm. The platen then drops and a new layer is jetted over the first. This process is repeated
thousands of times to build a part. Print time is determined by model height. A model 254 x 192
x 200mm can be built in under 30hrs.
Parts with undercuts, overhangs and other complex features are no problem due to the automatic
support structure demonstrated in the next animation.
The 19th century physicist Lord Kelvin (William Thomson) was the first to consider the
possibilities inherent in the controlled direction of liquid through electrostatic forces, and even
had a patent granted on this concept [9]. However, it is not clear from Kelvin's patent whether his
device would have created discrete drops or a stream of liquid. In any case, this was an idea
before its time, because there was no way to provide detailed instructions to steer the droplets,
and thus the device was incapable of drawing patterns except on a single line, limiting its
patterning to the simple dots and dashes of Morse code. It was almost 100 years before the next
development in this field occurred in the 1950s, when Siemens used this technique to replace
galvanometric chart recorders [10]. Major advances in both drop-generation and drop-placement
technology then occurred, developing inkjet printing further and making it practical for computer
graphics output. Advances in manufacturing technology reduced both the cost and size of these
printers, so that today, inkjet printers are seen as a relatively cheap personal or desktop printing
solution.
The main commercial applications for inkjet printing remain in graphics, product marking,
coding, and dating, among other conventional printing operations. However, in recent years there
Fig. 2. Schematic illustration of the operating principles of a continuous inkjet printer (CIJ).
DOD printers generate individual drops when required, and do not steer a drop in flight. Drop
placement occurs by mechanical positioning of the drop generator or substrate. Drops form
through the propagation of a pressure pulse in a reservoir behind the nozzle. This pressure pulse
Sanders ModelMaker
Both the thermoplastic material (Protobuild™) and the wax support material
(Protosupport™) are proprietary materials of Sanders.
Multi-Jet Modeling
Fast.
Office-friendly: non-toxic materials, small footprint, low odor.
Simple operation: operates as a network printer in an office environment.
Another product of 3D Systems from the makers of the SLA system, Multi-Jet Modeling™ uses a
96-element print head to deposit molten plastic for layering. The system is fast compared to most
other RP techniques, and produces good appearance models with minimal operator effort. The
main market that this system is targeted at is the engineering office where the system must be
non-toxic, quiet, small, and with minimal odor. The system is illustrated below:
• Fast: one to two vertical inches per hour, depending on layer density.
• Office-friendly: non-toxic materials, small footprint, low odor.
• Simple operation.
• Compared to SLA and SLS®, not as established.
The Z402™ is one of the fastest 3D printers known to Rapid Prototyping. The ability to produce
quick models means greater productivity for the lab and quick prototypes for customers. Since
manufacturing parts is easy, almost anyone in the lab can produce a quality part without
extensive Rapid Prototyping experience.
3-D printer.
a machine allowing the creation of a physical object from a three-dimensional digital
model, typically by laying down many thin layers of a material in succession.
Genisys Xs printer
In particular, we will be using an FDM system named The Genisys Xs. The Genisys 3-D
accepts its file in the same fashion as a regular FDM printer. The process begins with an .STL
file. Then the AutoGen software included performs functions on the file to prepare the part for
building. These functions include making sure the model has no errors, fixing any errors that
are present, part positioning, file slicing and support generation. AutoGen can also scale the
part by either of two methods, first by choosing a percentage of the file size, or by fitting the
part within a pre-determined volume up to 8 x 8 x 8 inches.
A line of cassettes supplies the system with our polyester compound. Each cassette holds 50
rectangular wafers. The wafers are fed into a pressurized, heated channel that supplies the
material to a viscosity pump. To ensure accuracy, the material is extruded through a .013"
diameter orifice at a controlled rate. Thin perimeter walls are created are created first, and then
the pump head fills in the area, creating a flat surface between the walls. This technique speeds
build time and maintains a good surface finish. The machine also calibrates itself each time it is
turned on to compensate for any deviations in angular position of the build table and gantry
alignments.
Supports created by AutoGen are built from the same polyester material. The system creates
perforations where supports adjoin the model, making it easy to snap off any required supports.
The Genisys printed models often require fewer supports than other systems' models due to
precise pump control.
Part 1: Preparing the Model 1. Start the AutoGen application from the QuickFind/Start
menu on your computer.
2. Under the File menu, click “Open STL…” and select the desired file. Note that
AutoGen may have issues with space characters in pathnames and filenames.
3. The model should now appear in the window. The red, green, and blue borders
correspond to the available build volume of the printer.
4. You can zoom in or out or rotate the view of the build volume by adjusting the
“thumbwheels”.
5. If the model appears dark, or is hard to see, under the View menu, select Draw
Style:Wireframe. The model will now be rendered without surface shading. The problem may
also be corrected by reversing the orientation of the surface normals on the model prior to loading
into AutoGen.
6. Resize your model if necessary using the Scale or Fit settings. The Fit menu allows
you to specify a cube size to which the size of the printout should be constrained.
7. As the model is built, it may need to have supports attached to it to keep it from
toppling over. Rotate the model to achieve the best orientation so as to minimize the complexity
of the support structure. Rotation values must be typed into the three fields labeled Rotation,
which represent X-, Y-, and Z-axis rotation angles in degrees. (See Figure 2.). A dark, hard-to-see
object. Rendered in wireframe. Figure 1 – Different Drawing Styles 8. Use the “Fill” menu to
determine whether to print a solid model (Normal), or to allow the printer to create a honeycomb
support structure (Sparse). The normal model offers increased strength. The sparse model offers
faster printing and cost efficiency as it requires less material. Part 2: Preprocessing 1. Under the
main menu select File:Print…. When prompted, click the checkbox for “Preprocessing Only”, and
then click OK. If preprocessing fails, try rotating the model to a different orientation (even if it
means adding supports), changing the fill type, or the part scaling. If this does not remedy the
problem, it may be necessary to change some aspect of the model’s design. 2. Once preprocessing
is done, the model can be “packed”. This is necessary only if multiple models or multiple copies
of a model are to be printed in a single print job. To pack the model select File:Print…, and select
“Pack” from the pull-down menu. Click OK and wait for the packing process to complete.
Epoxy Tools
Epoxy tools are used to manufacture prototype parts or limited runs of production parts.
Epoxy tools are used as:-
Moulds for prototype injection plastic
Moulds for casting
Compression moulds
Reaction Injection Moulds
The fabrication of moulds begins with the construction of a simple frame around the
parting line of RP model.
Sprue, gates and runners can be added or cut later on once the mould is finished. The
exposed surface of the model is coated with a release agent and epoxy is poured over
the model.
Aluminum powder is usually added to epoxy resin and copper cooling lines can also be
placed at this stage to increase the thermal conductivity of the mould.
Once the epoxy is cured the assembly is inverted and the parting line block is removed
leaving the pattern embedded in the side of the tool just cast.
Another frame is constructed and epoxy is poured to form the other side of the tool.
Then the second side of the tool is cured. The two halves of the tool are separated and the
pattern is removed.
Another approach known as soft surface rapid tool involves machining an oversized
cavity in an Aluminum plate.
Direct RT methods that satisfy these requirements are called methods for firm tooling or
bridge tooling.
RP processes for firm tooling fill the gap between soft and hard tooling
2nd group:
Solutions for hard tooling are based on fabrication of sintered metal steel, iron copper
powder inserts infiltrated with copper or bronze.
It includes RP methods that allow inserts for pre production and production tools to be
built.
These methods come under hard tooling
Combining the cast kirksite tooling process with RP and CAD improves prototype, bridge-to-
production and short-run parts injection molding.
Modern developments in RP techniques made way for the elimination of time-consuming hand
pattern-making and process streamlining-making cast kirksite tooling a superb tool for reducing
time-to-market with minimal capital expenditure.
In recent years, the injection molding of prototype, bridge-to production and short-run parts has
become quick and cost-effective thanks to the marriage of the cast kirksite tooling process with
RP and CAD technology. The designer's CAD file is used to produce a model by
stereolithography (SL) within hours and with minimal human intervention. Casting kirksite
cavities to net shape from SL master models translates the designer's intent directly into tooling
that provides the perfect rapid tools for prototype and bridge-to production injection molded
parts.
The Material
Originally developed for sheet metal forming tools in the automotive industry, kirksite material
is a zinc/aluminum alloy (94 percent Zn, 6 percent Al) with a melting point of 725 °F. Due to the
vapor pressure of the zinc, the material is almost immune to the gas porosity encountered with
other alloy systems and the shrinkage is approximately half that of aluminum, resulting in great
cast mold accuracy and repeatability.
Kirksite is machinable and weldable, making on the fly design adjustments possible. One of the
main benefits to this process is the ability to make geometric changes quickly and cheaply. In
extreme cases, if required for the application, several iterations of kirksite tools are possible at
less cost (in time and money) than one steel tool.
Tool life is dependent on many factors, particularly geometric complexity and the nature of the
material to be molded. Quantities of fifty to five hundred pieces are typical prototype runs, but
quantities as high as two hundred thousand pieces have been molded using cast kirksite dies.
The Process
Thermoplastic hand tool prototype with SLA master and cast kirksite cavity.
The process for making cast kirksite tools begins by producing a master pattern with shrink
adjustments, typically from a CAD file using the SL process. Joint boards are built to define
parting lines and a rubber or urethane impression is taken from the master to create patterns for
the core and cavity set. Then, a specially-formulated, plaster-base material is cast against the
core and cavity patterns to create plaster molds into which the kirksite is cast. The use of plaster,
which expands during setting, allows exact reproduction of even the finest pattern detail and
finish.
Once the kirksite is cast into the molds, the plaster is broken away. The molds are cleaned up and
machined to fit into a standard mold base with ejection and runner systems or they can be used
on a stand-alone basis. The molds are then mounted into a traditional injection press of the
appropriate tonnage and parts are run. Any required heating or cooling systems can either be cast
in place or added later by drilling.
The molds are kept as simple as possible and built for speed, not necessarily efficiency. Hand-
loaded loose pieces are used instead of mechanical pullbacks and slides. Four or five hand loads
are not uncommon, although this slows cycle time and increases unit cost.
Most of the design considerations used in creating injection molded parts are the same in
prototype part design-including draft, fillets, radii and wall thickness. Parts run in cast kirksite
molds generally range in size from a one-inch cube envelope to an approximate twenty-four-inch
cube.
As with any other tooling method, consideration must be given to process limitations to
maximize the success of the product. By introducing a casting process into your tool build, you
gain speed, but you must use a slightly wider tolerance band on non-critical dimensions since an
additional shrinkage factor must be included.
Areas that are critical to function must be identified and that detail can be CNC machined into
the mold with great accuracy. Cosmetic appearance expectation must be measured and
appearance-critical areas can be enhanced through mold finishing/polishing and appropriately
engineered cooling and ejection systems.
In most cases, parts will have an appearance very close to the production parts and many OEMs
have used the parts to market their product ahead of full-scale production. Typically, companies
have used prototypes for functionality testing in addition to product previews at industry
tradeshows or in trade publications.
Many new hand tools or products you see on the Web or in a catalog have been made with
prototype molds. Consumer products' companies with very sophisticated assembly lines are able
to set up and fine-tune their lines long before an actual production unit is manufactured, enabling
a seamless product launch.
Companies with very low annual volumes also are able to use thermoplastic parts in their design
by using cast kirksite molds for their entire production run. Many niche and high-end products
have an annual quantity requirement insufficient to justify steel tooling. For intermediate
quantities, steel inserts in localized high wear areas can enhance tool life at minimal cost.
Duplicate core/cavity sets also are easily made from the master pattern for a cost-effective way
to extend production capabilities.
Parts can be molded in any thermoplastic resin while prototype parts in a range of shapes and
sizes are routinely produced in two to five weeks. Part features that are not in the direction of
draw are achieved with hand loads, which allow complex configurations.
This technique is very useful to anyone developing new products with thermoplastic parts.
Design teams can now get fully testable prototypes in a few weeks and begin the design
refinement loop at a much earlier date. Manufacturers of consumer products are able to get UL
and similar test approvals quickly-concurrent with test marketing and production tool builds.
The nature of the casting process allows almost complete design freedom with no penalty in
production time. All the detail in the original file is translated into a 3-D SL model and then
traditional casting technology is used to transfer this detail to the injection mold. The technique
has been used through a wide cross-section of today's leading products-including automobiles,
hand tools, small appliances, computers, telecommunications equipment, medical diagnostic test
equipment and audio/home entertainment gear.
Cast kirksite tools also can be used as molds for many other plastic molding processes with
similar success. When quantities make sense (i.e., short runs), cast kirksite tools have been used
for blow molding, rotational molding, compression molding and RIM (reaction injection
molding). The molds can be used for many shapes when quantity requirements cannot justify
investing in machined aluminum or steel tooling.
UNIT-6
Sand Casting Tooling
Sand casting is often used to produce large metal parts with low requirement of
surface quality.
When employing rapid prototyping techniques it is much more convenient to build patterns
which include compensation for shrinkage of the castings as well as additional machining
stock for areas requiring machining after casting.
The other benefits are that it significantly reduces lead time and increase pattern
accuracy.
Soft Tooling:
It can be used to intake multiple wax or plastic parts using conventional injection
moulding techniques. It produces short term production patterns. Injected wax patterns
can be used to produce castings. Soft tools can usually be fabricated for ten times less
than a machine tool.
Hard Tooling:
Patterns are fabricated by machining either tool steel or aluminum into the negative
shape of the desired component. Steel tools are very expensive yet typically last
indefinitely building millions of parts in a mass production environment. Aluminum tools
are less expensive than steel and are used for lower production quantities
This "QuickCast Tooling" process has the potential for truly dramatic cost and time
savings. Data presented in this paper document the actual time and money saved by Ford
on this project alone. Ultimately, QuickCast Tooling should enable rapid and economical
generation of core and cavity inserts for either direct injection molding of 156 end-use
production plastic parts, manufacturing large quantities of investment casting wax
patterns, or as dies for direct die casting of production metal components. However, in
order for this application to provide really substantial cost and time savings, it is essential
that the accuracy and surface finish ofthe SL generated patterns continue to improve.
With e(90) values currently at 91 micrometers, coupled with the surface finish ofthe latest
QuickCast patterns, we are now moving "into the ballpark" of QuickCast Tooling. As
e(90) is continuously diminished and "stair-stepping" is further reduced, this application
will begin to grow rapidly~ driven by the remarkable economic and schedule benefits
attainable. When e(90) moves below 40 micrometers and SL pattern surface finish begins
to approach that ofmachined tool steel, we believe that Rapid Tooling will become a
dominant growth mechanism ofRP&M. While these levels of pattern accuracy and
surface finish may still be a few years away, they are coming. This paper describes a
QuickCast
QuickCast, a 3D Systems proprietary process, replaces traditional wax patterns for investment
casting with stereolithography (SLA) patterns created in a robust, durable material, without
tooling and without delay. The net result is QuickCast patterns in as little as 2 to 4 days and
quality metal castings in 1 to 4 weeks.
The QuickCast part resembles a beehive hatch pattern and ends up being about 80% hollow. It
will burn out in the investment casting process with very little residue.
PROCESS DESCRIPTION
Copper Polyamide:
Copper polyamide is a new metal plastic composite designed for short run tooling
applications (100 to 400 parts) from common plastics.
Tooling inserts are produced directly in the SLS machine with a layer thickness of 75
µm.
Subsequent finishing is necessary before their integration in the tool base.
No furnace cycle is required and unfinished tool insert can be produced in a day.
Image via
The basic idea behind rapid prototyping is one of quick cyclical creation, revision, and iteration–
as represented in the image above. This process allows you to get from idea to working product
as quickly as possible.
Every problem encountered along the way is acknowledged and dealt with as fast as possible,
ideally resulting in a better product on a faster timeline. When this philosophy is carried on after
launch, it should lead to a product that is more agile than the competition because the
development process is better equipped to respond to change.
When it comes to practicing rapid prototyping there are three stages of idea development that can
be used to varying levels of effectiveness before a final product is put into production. They are
also typically referred to as high, medium, and low fidelity; which is meant to reflect how close
to the final product they get you.
Regardless of which approach you choose to take, one or more of the tools/techniques below
should be able help. The programs I’ve collected all allow you to create wireframes and/or
working prototypes of varying degrees of fidelity. I didn’t include anything but the above link for
UI Stencils for sketching since that one basically takes care of itself–so long as you have pencil
and paper.
As per usual, I haven’t ranked these options in any particular order, merely listed them here for
you to see what’s available and choose the option or options that best suit your specific needs.
Speaking of which, I’d highly recommend reading the article Prototyping Your
Workflow from A List Apart. Its author gives good advice on brining new prototyping tools and
techniques into an existing workflow by adopting the same iterative mentality as prototyping
itself.
In terms of the tools/techniques featured below, there are without a doubt many more that could
have made this list and if your favorite one is not mentioned then I hope you will take a few
For additional information, see Wohlers Report 2017, an annual worldwide progress report on
the additive manufacturing and 3D printing state of the industry.
STL files
STL (STereoLithography) is a file format native to the stereolithography CAD software
created by 3D Systems. STL has several after-the-fact backronyms such as "Standard
Triangle Language" and "Standard Tessellation Language".
In a nutshell, an STL file contains data describing the layout of a three-dimensional object. These
files are usually generated by a computer-aided design (CAD) program. “.STL” is the file
extension of the STL file format.
The STL file format is the most commonly used file format for 3D printing. When used in
conjunction with a 3D slicer, it allows a computer to communicate with 3D printer hardware.
Since its humble beginnings, the STL file format has been adopted and supported by many other
CAD software packages, and today is widely used for rapid prototyping, 3D printing, and
computer-aided manufacturing. Hobbyists and professionals use it alike.
The meaning of the file extension .STL has been lost to the mists of time.
In software terms, the STL file is perhaps the single most important item of any 3D printing
workflow. It contains the 3D model that is used to make a physical object, and as a standard data
format, it has reigned supreme for nearly thirty years.
In simple terms, the STL file format uses a series of linked triangles to recreate the surface
geometry of a solid model.
For a basic model, its surfaces can be represented using a few triangles. For higher resolution
models, more triangles are required to replicate the surface of the model. The more triangles that
make up a model, the bigger the file size and the more detailed the object.
The STL file format can define complex shapes (mathematically speaking, polyhedrons with any
polygonal facets). In practice, it is mostly used to describe the layout of triangles in a virtual
space.
The STL file format was invented by the Albert Consulting Group for 3D Systems in 1987, in
turn, to support the stereolithographic 3D printer invented by Chuck Hull. The STL file format
made it possible to transfer three-dimensional CAD models to 3D Systems’ very first
commercial 3D printers, the StereoLithography Apparatus.
Since this initial release, the technical specifications of the STL file format have remained
virtually unchanged.
Unfortunately not. Only a 3D design that’s specifically made for 3D printing is 3D printable. The
STL file is just the container for the data, not a guarantee that something is printable.
3D models suitable for 3D printing need to have a minimum wall thickness and a “watertight”
surface geometry to be 3D printable. Even if it’s visible on a computer screen, it’s impossible to
print something with a wall thickness of zero.
There’s also the consideration of overhanging elements on the model. Look at the ALL3DP logo
in the picture above; if the model is printed upright, then overhanging elements with more than a
45-degree angle will require supports (which you can see in green).
When downloading an STL file that you haven’t created yourself, it’s worth taking the time to
verify that it is indeed 3D printable. This will save you a lot of time and frustration (and wasted
filament).
In a word: simplicity. Even the most complex design can be reduced to simple geometrical
forms.
Open: The STL file format is non-proprietary, and allows for both (human readable) ASCII and
(smaller) binary representations.
Vector-based: As the STL file format describes geometrical figures, it is scalable, which is a
huge advantage if you want to change the size of a 3D object.
Universal: STL files can be used with nearly every 3D printer or CAD program.
Readable: Users can code up an STL file very quickly, and can read or write to it very easily.
Almost all of today’s CAD systems are capable of producing STL files. For the user the process
is often as simple as selecting “File,” “Save As” or “Export,” and then clicking on “STL”.
In turn, a large software and service ecosystem has grown around repairing and manipulating
STL files.
There are a quite few. For starters, STL files are limited to describing only the surface geometry
of a three-dimensional object. There is no representation of color, texture, material, substructure,
or other attributes typically found in other CAD model formats.
With the evolution of additive manufacturing technology from primarily single-material, low-
detailed shapes to multi-material geometries in full color (with functionally graded materials
AND micro-structures), there’s a growing need for a standard interchange file format that could
support these features.
Other things lacking from the STL file format is the inclusion of metadata (such as authorship
and copyright information), little or no file security, and the inability to detect or fix errors in the
surface mesh.
To put it kindly, the STL file format simply hasn’t kept pace with new developments and
features available to modern 3D printers.
For 3D printing, the STL file has to be opened in a dedicated slicer. What’s a slicer? It’s a piece
of 3D printing software that converts digital 3D models into printing instructions for your 3D
printer to create an object.
All of this information is then bundled up into a GCode file, the native language of your 3D
printer. Slicer settings do have an impact the quality of your print so it’s important to have the
right software and settings to get you the best quality print possible.
Once the GCode has been uploaded to your 3D printer, the next stage is for those separate two-
dimensional layers to be reassembled as a three-dimensional object on your print-bed. This is
done by depositing a succession of thin layers of plastics, metals, or composite materials, and
building up the model one layer at a time.
More information: 3D Slicer Settings for Beginners – 8 Things You Need to Know
Yes, it is entirely possible to edit an STL file and convert the STL to another file format. Because
the format is open, there is nothing to prevent you from changing the contents of a file. Actually,
the process of editing is quite easy. We have a dedicated article on this topic: 7 Free STL
Editors (How to Edit and Repair STL Files)
There are several programs which can help with repairing a broken STL file. For example,
Netfabb Basic is a great tool for repairing the most common STL file problems. You find more
information on these programs in our article: 20 Best 3D Printing Software Tools (Most are
Free)
There are many repositories, marketplaces and search engines on the web containing literally
millions of free STL files. You can refer to our regularly updated list — 34 Best Sites for Free
STL Files & 3D Printer Models — or you can choose one of these models to get started: 45
Cool Things to 3D Print Which Are Actually Useful
The STL file format is not the only format used in 3D printing. There are over 30 file formats for
3D printing. Most important is the OBJ file format, which can store color and texture profiles.
Another option the is Polygon file format (PLY), which was originally used for storing 3D
scanned objects.
More recently, there have been efforts to launch a new file type by The 3MF Consortium, which
is proposing a new 3D printing file format called 3MF. They claim it will streamline and
improve the 3D printing process.
To implement it, Microsoft has partnered up companies like Autodesk, HP, and Shapeways to
make their vision a reality. More details on the 3MF Consortium can be read on their website,
together with preliminary documentation about the 3MF file type on their GitHub page.
It’s far too early to say whether this will become widely adopted, however, so we’d
recommend sticking with the STL file format for the foreseeable future.
The reason the STL file format lacks color information is simple. When rapid prototyping
evolved in the 1980’s, no one thought of color printing. Nowadays, 3D printing materials and
processes have evolved rapidly. Some allow you to print in full-color – just think of sandstone
3D selfies, as pictured above.
Some software packages (i.e. VisCAM and SolidView) use the two “attribute byte
count” bytes at the end of every triangle to store a 15-bit RGB color information.
Materialise Magics software uses an 80-byte header at the top of the file to represent the
overall color of an entire part.
As mentioned, the 3MF Consortium wants to add color information to their new 3D printing file
format 3MF. They claim it will streamline and improve the 3D printing process.
No, it can not. The STL filr format wasn’t invented with materials in mind. Only the 3MF file
format to adds material data to the STL file, but it’s not yet commonly used yet.
SolidView/Pro RP is the most robust of the SolidView family of products and is designed for
companies doing their own rapid prototyping work. SolidView/Pro RP offers all SolidView/Pro
magic’s
Magics is an essential tool for anyone that runs a 3D printer or rapid prototyping machine. This is
particularly true for a RP service bureau where STL files of varying quality has to be processed.
Some times the parts are too large for the machine and have to be built in sections. That is when
Magics becomes very handy..
Magics rapid prototyping software enables you to import a wide variety of CAD formats and to
export STL files ready for rapid prototyping, tooling and manufacturing. Its applications include
repairing and optimizing 3D models; analyzing parts; making process-related design changes on
your STL files; designing fixtures; documenting your projects; production planning and much more.
Major features:
• Healing of STL files into a solid mesh suitable for rapid prototyping
• Cutting STL models into smaller sections when they are too big for the RP machine
• Shrink Wrap a new external STL skin onto a poor STL, very useful with architect models
magic’s
Rapid Prototyping isn't just about owning a machine that can build parts quickly. It includes
other elements, beginning with quoting a job, through data conversion and work preparation, all
the way to quality control. All of these elements have to work in harmony to achieve a common
goal: speed without sacrificing accuracy. Over the past few years, Magics RP has proven to the
rapid prototyping world that it's an indispensable software tool for achieving that goal. Magics
RP's powerful, efficient 3D tools enable you to deliver high quality prototypes with the shortest
lead times. At the same time, Magics provides you and your clients with full documentation of
the process Magics simplifies time-consuming data conversion conversion. Neither can your
clients. Magics RP allows you to get right to work on a file with a very high triangulation
quality. To further improve communication between you and your customers, Materialise has
developed a compression format called MGX. MGX shrinks an STL to about 1/20 of its original
size. The MGX format thus saves space and speeds up distribution, download and transfer of
STL files. With Magics, you can easily zip STL files and unzip MGX files. Magics RP software
can import most standard 3D formats - STL, VDA, IGES, STEP, VRML - and native CAD
formats like UG/Parasolid and Catia. Growing numbers of customers also work with scanned
data. To meet their needs, Magics offers the import and export of point clouds. The imported
files are converted to a digital CAD structure according to a userdefined accuracy. The
conversion process includes correction of common errors. The resulting STL file is ready to
produce prototypes or tools without the need for further conversion. Magics RP is a must for
every RP service bureau. You can't afford to lose time in Magics calculates a comprehensive
quote in seconds Magics has excellent 3D visualisation capabilities, instantly giving you a clear
picture of a part's intricacies. With Magics' build time estimator, you can assess costs and plan
machine capacity. Simply input the necessary dependencies, such as volume or surface, and you
MIMICS
Materialise Mimics is an image processing software for 3D design and modeling,
developed by Materialise NV,[1] a Belgian company specialized in additive
manufacturing software and technology for medical, dental and additive manufacturing
industries. Materialise Mimics is used to create 3D surface models from stacks of 2D
image data. These 3D models can then be used for a variety of engineering applications.
Mimics is an acronym for Materialise Interactive Medical Image Control System. It is
developed in an ISO environment with CE and FDA 510k premarket clearance.
Materialise Mimics is commercially available as part of the Materialise Mimics
Innovation Suite, which also contains 3-matic, a design and meshing software for
anatomical data. The current version is 19.0, it supports Windows 10, Windows
7, Vista and XP in both x32 and x64.
Internet based software,
Updated ACIS R1 Support
AutoCAD ACIS data up to R1 - 2017 1.0 (2D & 3D).
We decided to compile a list of tools which makes it easier to collaborate and get feedback on
design work.
We hope that among these design collaboration tools you’ll find one that will help you
collaborate more efficiently on design work both remotely but also in-house.
The criteria for picking these tools was that the tool had to have features for design collaboration
but also be useful in a web design process. Please share links to any tools that we’ve missed in
the comments below!
It is undoubted that UI/UX design is an important aspect of making a website or application work.
Creating and improving products based on prototypes is growing in strength and the prototyping
tools for designers are comes in all shapes and sizes these days. With so many UI/UX prototyping
tools out there how do you know which tool to choose? Choosing the right tool will bring you
twice efficiency with half the effort.
So first things first, it’s important to know exactly what you want. Ask yourself a few questions
before making your choice.
2. Usage: Are you prototyping websites, mobile apps, desktop apps, or all of the above?
3. Fidelity: What is the requirement of your prototypes fidelity? Are wireframes that shows the
app layout and structure sufficient, or do you need something that supports more details and
complex interactions?
4. Sharing: Collaboration is key when it comes to design. Thus, it’s important to consider the
collaboration features supported by the prototyping tools, ability to share your prototype with
others and/or work collaboratively on the prototype.
5. Professional Skills Requirement: Are you an expert or newbie in this filed? Is programming
knowledge or coding required? Are you experienced in visual design?
6. Cost: How much are you prepared to pay for design tools?
There are other things to take into account as well. Below I’ve outlined what I think are the best
prototyping tools worth trying in 2016 and hope you find out the one fit your exact need.
Unit 8:
The application of the two technologies: reverse engineering and rapid prototyping is emerging
rapidly in the medical applications. These engineering methods have especially shown fast
advancement in the following applications: in very complex preparation of computer aided
surgery, computer guided implantology, non-invasive diagnostic from CT and MRI scans, design
of customized implants, maxillofacial surgery, esthetic and reconstructive plastic surgery,
orthopedic surgery, etc. This research has a multidisciplinary approach; it requires a team work
of experts from various scientific fields such as CAD design and virtual engineering, digital
image processing, medicine, implantology. Only a very few applicative pioneer steps have been
made so far in Republic of Srpska, Bosnia and SE Europe in general. The aim of this research is
to make a contribution to the optimization of all three phases: preprocessing, processing and
post-processing in the process chain of reverse engineering – rapid prototyping in the medical
applications. The optimal process of rapid prototyping has been defined for different medical
input data and formats. The process includes internal 3d reconstruction of CT and MRI scanning
in DICOM format, such as applications in orthopedic surgery, maxillofacial surgery, prosthetic
dentistry, such as complex or total prosthesis, as well as the external surface reconstruction by 3d
scanning, such as esthetic surgery and reconstruction plastic surgery or dentistry based on 3d
scanning from elastic silicone impression.
Accuracy of a model is influenced by the errors caused during tessellation and slicing at
data preparation stage. Decision of the designer about part deposition orientation also
RP processes are integrated manufacturing processes that include CAD/CAM, control of laser devices,
materials, manufacturing parameter setup, and post-processing. Individual process can introduce some
errors one way or another [2, 3, 4, 5, 15], as explained below. These errors severely reduce RP product
accuracy and obstruct its further applications in rapid tooling and functional part fabrication. 1.
CAD/CAM induced error. Most rapid prototyping systems use the de facto standard STL CAD file format
of solid representation to define parts to be built. However, STL files pose the problems of dimension,
form and surface errors resulting from approximation of three-dimensional surfaces by triangular facets.
Although a large number of facets can be used to reduce these errors, doing so will result “Parametric
Process Optimization to Improve the Accuracy of Rapid Prototyped Stereolithography Parts,” Jack Zhou,
Dan Herscovici & Calvin Chen, International Journal of Machine Tools and Manufacture, No.40,
2. Laser beam width induced error. The laser beam used to create parts is of a finite width,
though the file used to drive the machine represents the edges as zero-width lines. The width of
this beam can be compensated for in the laser beam scan control software, but the beam width is
not constant from machine to machine and even not the same on a single machine over time.
This induces part errors.
3. Material shrinkage error. SLA part accuracy is a direct result of the resin properties. Many
researchers are striving to develop new resins that offer low shrinkage and high dimensional
stability. The earlier resins available from 3D Systems Inc. are primarily limited to the Acrylate
base resins with relatively large shrinkage (5%-7% in volume), causing severe distortions of the
finished parts.
5. Postprocessing error. SL parts are designed to be post-cured as soon as they are built,
otherwise green creep distortion, which results from the residual internal stress generated during
the SLA building cycle, will occur. An accumulation of the above five errors usually causes 250-
500 mm dimensional error and very unpleasant surface roughness, which make RP products
unacceptable in many applications for a long time.
IMPROVEMENT OF RP ACCURACY
Fortunately in the last several years, many research efforts have been dedicated to RP
technology and the accuracy problems have been improved significantly. In CAD/CAM a new
SLC file format was defined by 3D Systems in 1992. Unlike the tessellated solid STL
representation, it is a 2-1/2D contour representation of the model boundaries within each layer.
SLC data can be generated from various sources such as CAD solid or surface models or CT
scanners. The SLC file format can virtually eliminate the problem of translating a part from the
original representation to an intermediate tessellation form, where the error is induced. Some
other approaches to eliminating STL format error are also under investigation such as NURBS
and direct slicing methods [6]. In laser beam width, a better laser beam control mechanism and
“Parametric Process Optimization to Improve the Accuracy of Rapid Prototyped
Stereolithography Parts,” Jack Zhou, Dan Herscovici & Calvin Chen, International Journal of
Machine Tools and Manufacture, No.40, 1-17,1999 4 beam width compensation software has
been used, which reduces the error to a minimum. On the materials side, in early 1994 a
significant advance was accomplished when 3D Systems and Ciba Geigy Corporation introduced
an Epoxy resin called XB5170. Unlike the Acrylate resin, the small shrinkage of XB5170 (2%-
3% in volume) makes it possible to build a stable and accurate part. In postprocessing, along
with XB5170 resin, 3D Systems also developed a new part build style ACES (Accurate, Clear,
Epoxy, Solid). This is accomplished by completing and uniforming polymerization during the
part building process, virtually eliminating post-cure distortion and internal stresses. The only
problem left on which not much work has been done is RP machine parameter setup. Many
factors contribute to the output accuracy and part build time. However, among these there are
only a selected few that are adjustable by users. On the surface they appear to be simple to
adjust, but users quickly realize that small adjustments may have large output effects.
Furthermore, changing combinations of parameter setup turns into a guessing game, where only
after many experimental runs gives a glimpse of what the settings should be for different
situations
In the actual RPT part-building process there are additional errors which are affected by many
process-related parameters, e.g. the machine path control accuracy, tool scan speed uniformity,
tool shape stability, platform control accuracy, material properties, part thermal distortion,
material feed uniformity, fixture stability, glue thickness (in LOM process) uniformity, and part
thermal shrinkage and distortion. These errors interact with the DPE and when combined they
determine the final geometrical accuracy of the part produced. There are three possible effects of
these fabrication errors on the final geometry of the part: 1. Geometrical errors generated in the
x- and y-directions only which are primarily associated with the scan path and tool shape control
accuracy as shown in Fig. l(a). 2. Geometrical errors in the z-direction which are mainly related
to the platform displacement accuracy and materials thickness uniformity (e.g. in LOM and SLS
processes) as shown in Fig. l(b). 3. Geometrical errors in all directions (Fig. l(c)) as a result of
scan speed variation (acceleration and deceleration), material flatness variation (e.g. in LOM
process), thermal distortion of the part and other assembly errors. It can be seen that the errors
resulting from the actual part building process can alter the extent of theoretical errors relating to
the staircase and containment problem defined by the fabrication method. For the purpose of
error analysis, all the errors generated during the part-building process are now defined as the
disturbance error.
(a) Errors in the x,y-plane (e.g. contour geometry error). (b) Errors in the z-direction (e.g. layer
thickness error). (c) Errors in x-, y-, and z-directions (e.g. layer flatness variation) 3.
METHODOLOGY Geometric dimensioning achieves the goal of identical
PART FINISHING
Poor surface quality of RP parts is a major limitation and is primarily due to staircase effect.
Surface roughness can be controlled below a predefined threshold value by using an adaptive
slicing [2](Pandey et al., 2003b). Further, the situation can be improved by finding out a part
deposition orientation that gives minimum overall average part surface roughness [11](Singhal et
al., 2005). However, some RP applications like exhibition models, tooling or master pattern for
indirect tool production etc. require additional finishing to improve the surface appearance of the
part. This is generally carried by sanding and polishing RP models which leads to change in the
mathematical definitions of the various features of the model. The model accuracy is mainly
influenced by two factors namely the varying amount of material removed by the finishing
process and the finishing technique adopted. A skilled operator is required as the amount of
material to be removed from different surfaces may be different and inaccuracies caused due to
deposition can be brought down. A finishing technique selection is important because different
processes have different degrees of dimensional control. For example models finished by
employing milling will have less influence on accuracy than those using manual wet sanding or
sand blasting. (a) Thicker bottom layer (b) Deformed hole boundary Figure 11: Over-curing
effects on accuracy in Stereolithography [3] (after Pham and Demov, 2001) 4. SELECTION OF
PART DEPOSITION ORIENTATION This is one of the crucial decisions taken before slicing
the part and initiating the process of deposition for a particular RP process. This decision is
important because it has potential to reduce part building time, amount of supports required, part
quality in terms of surface finish or accuracy and cost as well. Selection of part deposition
Methods to Improve Surface Finish All the methods for improving surface finish can be divided
into four categories, namely: 1. Optimization of build orientation 2. Slicing strategy (layer
thickness). 3. Fabrication parameters optimization 4. Post-treatment. In first three methods are
used before making the FDM parts but the fourth method is used after making the part. 2.1.
Optimization of Build Orientation The orientation at which the part is built, can have a
significant effect on the surface finish of the part. Different methods have been developed by
various researchers to find the optimal orientation for the fabrication of part on RP machine.
Vijay et al. [6] determined the optimal surface finish of model built by varying build orientation,
layer thickness and keeping other parameters constant of FDM process using experimental
design technique. Experiments were conducted using a fractional factorial design with two levels
for layer thickness and three levels for orientation factor. The authors concluded that for 20 and
45 degrees built orientation the roughness value is directly proportional to the layer thickness but
for 70 degree built orientation roughness value is decreased as the layer thickness is increased.
Allen & Dutta [7] and Sreeram et al. [8] developed a method for automatically computing the
support structure for the part in layer manufacturing and then deciding the best orientation from a
candidate list of orientations The authors developed a method to determine the optimal
orientation based on variable slicing thickness in layered manufacturing for a polyhedral object.
Lan et al. [9] determined deposition orientation for stereolithography parts based on the
considerations of surface quality, build time and complexity of the support structures. Surface
quality was evaluated either by maximizing the area of non-stepped surfaces or by minimizing
the area of worst quality surfaces. Build time was indirectly assessed by using the height of the
part in the deposition direction. Support structure was minimized by minimizing number of
supported points. The author discussed the orientation problem from geometric and algorithmic
points of view, and established decision criteria for the determination of good fabrication
orientation. In a study, Frank and Fadel [10] proposed an expert system tool that considers the
various parameters that affect the production of the prototype and recommends the best direction
of building the part based on both the user’s input and a decision matrix implemented within the
Additive Manufacturing (AM) is the process of part building by stacking layers of material on
top of each other. Various challenges for a metal powder based process include reducing the
staircase effect which leads to poor surface finish of the part, and minimal use of support
structures for regions with overhangs or internal hollow volumes. Part build orientation is a
crucial process parameter which affects part quality, in particular, Geometric Dimensioning &
Tolerancing (GD&T) errors on the part, the energy expended and the extent of support structures
required. This paper provides an approach to identify an optimal build orientation which will
minimize the volume of support structures while meeting the specified GD&T criteria of the part
for a DMLS based process. Siemens PLM NX API is used to extract the GD&T callouts and
associated geometric information of the CAD model. The regions requiring support structures
are identified and a Quadtree decomposition is used to find the volume of support structures. The
mathematical relationships between build orientation and GD&T are developed as part of a
combined optimization model to identify best build orientations for minimizing support
structures while meeting the design tolerances. The feasible build orientations along with the
corresponding support structures are depicted using a visual model.
Metal powder based Additive Manufacturing is gaining popularity in the aerospace, medical,
electronics and automobile industry, as intricate components can be built with ease. The process
begins by slicing the CAD model to obtain a 2D contour at each level of the build axis, which is
fixed Procedia Manufacturing Volume 1, 2015, Pages 343–354 43rd Proceedings of the North
Department of Mechatronics Engineering.Page 81
RAPID PROTOTYPING
10MT81
American Manufacturing Research Institution of SME http://www.sme.org/namrc as the z-axis.
Starting from the base 2D contour, a user defined slice thickness is added cumulatively at
successive slicing planes. This layer by layer stacking gives rise to an error called the staircase
effect which diminishes the surface finish of the part. Achieving part accuracy is currently one of
the key constraints in AM. Slice thickness, part build orientation, thermal errors, support
structures are a few major parameters which affect part accuracy. In this paper, the effect of part
build orientation on support structures volume and part accuracy will be addressed. Build
orientation is a crucial parameter since it will affect the tolerance errors, energy expended and
the volume of support structures required. Support structures are an integral part of this process
as it is necessary to account for possible overhangs or internal hollow volumes which might not
provide sufficient support to the overhanging layers. It is essential to minimize the use of these
supports as reduced contact area between the part and these structures will result in better part
quality and also reduce the post processing efforts (Dutta and Kulkarni, 2000). This paper
discusses a methodology to detect the regions requiring support and calculate the volume of
these support structures at various orientations. This information is then used to find an optimal
build orientation, having minimum support structures while satisfying the tolerance callouts. The
tolerances covered in this paper are Perpendicularity, Parallelism, Angularity, Total Runout,
Circular Runout and Conicity. Assuming a fixed slice thickness, mathematical relations are
developed between the tolerance errors and part orientation. A combined optimization model is
used to obtain the optimal build angle which is then verified using the graphical representation
adapted from Arni and Gupta (Arni and Gupta, 2001) and Paul and Anand (Paul and Anand,
2014). Finally, the volume of support structures at different orientations is plotted on a unit
sphere depicting different build orientations which can act as a tool for visualizing and
comparing extent of supports. A combined visual representation of volume of support structures
and the tolerances satisfied at each orientation is also presented.