Project PPT by Ghananand

GLOBAL TECHNICAL CAMPUS
1. INTRODUCTION
2. DESIGN PROCESS
3. DEVELOPMENT RAPID PROTOTYPING TECHNOLOGY
4. WHY RAPID PROTOTYPING

5. METHODOLOGY
6. PRINCIPLE & STL FILE AS PROTOTYPE DATA
7. RP TECHNIQUES
8. MATERIALS
9. APPLICATIONS
10. BENEFITS & LIMITATIONS OF RP TECHNOLOGY
11. FUTURE DEVELOPMENT
12. CONCLUSIONS
13. REFERENCES
“AN ORIGINAL, FULL- SCALE, AND USUALLY WORKING MODEL OF A NEW PRODUCT
OR NEW VERSION OF AN EXISTING PRODUCT.”
Traditional Methods
CAD Only
Rapid Prototyping
RP&M Enables the Making of
Physical Models From
Computer-Aided Design
(CAD) Data
ENGINEERING DESIGN AND RAPID PROTOTYPING: COURSE PEDAGOGY
HISTORICAL DEVELOPMENT OF RAPID PROTOTYPING AND RELATED TECHNOLOGIES
Year of Inception Technology
1770 - Mechanization
1946 - First Computer
1952 - First Numerical Control (NC) Machine Tool
1960 - First commercial Laser
1961 - First commercial Robot
1963 - First Interactive Graphics System
(Early version of Computer-Aided Design)
1988 - First commercial Rapid Prototyping System
THE DEVELOPMENT OF RAPID PROTOTYPING IS CLOSELY TIED IN WITH

THE DEVELOPMENT OF APPLICATIONS OF COMPUTERS IN THE INDUSTRY.
Because product designers would like to have a physical model of a new part or
product design rather than just a computer model or line drawing .
1. To increase effective communication
2. To decrease development time.
3. To decrease costly mistakes.
4. To minimize sustaining engineering changes.
5. To extend product lifetime by adding necessary features and eliminating
redundant features.
The trends in manufacturing industries continue to emphasize the following:-

1. Increasing number of variants of products.
2. Increasing product complexity.
3. Decreasing product lifetime before obsolescence.
4. Decreasing delivery time.
Rapid Prototyping improves product development by enabling better

communication in a concurrent engineering environment.
Any RP part is produced by adding materials
3D object is designed to 2D Geometric modular Part mathematically
sectioned
paths are generated. curing parts to instruct the machine
After a layer is built, a new layer is built layer by layer from bottom to top.
Thus RP activities consist of data preparation & model production.
STL file as a prototype data: - 3D Systems developed the STL file format to transfer
geometry to the SLA machine. STL files are faceted representations of data composed
of triangles. The data for the STL file can come from a variety of sources: a solid CAD
model, MRI (magnetic resonance imaging) and x-ray data, and laser and digitizing arm
scans.
RAPID PROTOTYPING
LIQUID BASED RP SYSTEMS POWDER BASED RP SYSTEMS SOLID BASED RP SYSTEMS
1. SOLID GROUND CURING 1. SELECTIVE LASER SINTERING 1. LAMINATED OBJECT

2. THREE DIMENSIONAL PRINTING MANUFACTURING (LOM)
2. STEREOLITHOGRAPHY
2. FUSED DEPOSITION MODELING
3. DROPLET DEPOSITION MFG.
1.START PROCESS- INITIAL LAYER
ADDED TO PLATFORM
2.AFTER ADDING SEVERAL LAYERS
-PART GEOMETRY GRADUALLY
TAKES FORM
Mirror
Optics Laser
Powder
Bed
Piston
Leveling
Powder Roller
Bed
Powder Feeding
System
FDM GENERATED CROSS SECTION
Filament
Heated
FDM Head
Molten
Filament
Supply
NOTICE THAT THE FDM FILAMENT CANNOT CROSS ITSELF, AS THIS

WOULD CAUSE A HIGH SPOT IN THE GIVEN LAYER
1. DESIGN
2. ENGINEERING ANALYSIS AND PLANNING
3. TOOLING AND MANUFACTURING

TO PRODUCT DESIGNER  REDUCE TIME
 EARLY DESIGN FLAW DETECTION

TO THE MANUFACTURER
 DESIGN AND FIT
TO THE MARKETER
 SUITABILITY OF MECHANICAL PROPERTIES
TO THE CONSUMER
 MANUFACTURING PROCESS CAPABILITIES
LIMITATIONS
 IMPROVED ABILITY TO VISUALIZE
SKILL
 IMPROVE PRODUCT QUALITY
 ACCURACY
 COMMUNICATION
 HIGH COST EQUIPMENT
 CAPABLE TO BUILD MOST COMPLICATED PARTS
 PART STRENGTH IS LESS
 LIMITED VARIETY OF MATERIALS

 SPEED
 SURFACE FINISH
 MATERIAL
 FUNCTION TESTING
 SIZE CAPACITY
The dynamics of markets, technology, and competition have brought changes to
virtually every market sector and have made new product development one of the
most powerful business activities. Product features quality, cost & time to market are
important factors of a manufacturer to remain competitive. RP system offer the
opportunities to make products faster & usually at lower cost rather then using
conventional methods. Since RP can substantially reduce the product development
cycle time, more & more business is taking advantages of speed at which product
design generated by computers can be held, viewed, studied, tested and compared. RP
is rapid development area. Capacities & potential of RP technologies have attached a
wide range of industries to invest in these technologies.
[1]. Chua, C.K., (1994) “Three-dimensional rapid prototyping technologies and key development areas,”
Computing and Control Engineering Journal Vol 5(4): pp.200–206.
[2]. Chua, C.K., (September 1987): “Solid modeling — A state-of-the-art report,” Manu-facturing Equipment
News pp.33–34.
[3]. Metelnick, J. (1991), “How today model/prototype shop is helps designers use rapid prototyping to full
advantage, “Society of Manufacturing Engineers Technical Paper Vol. MS91-475.
[4]. Lee, G. (1995), “Virtual prototyping on personal computers, ”Mechanical Engineering Vol.17(7) pp.70–
73.
[5]. Kochan, D., (1992) “Solid freeform manufacturing — Possibilities and restrictions , ”Computers in
Industry Vol.20 pp.133–140.
[6].Kochan, D. and Chua, C.K. (1995), “State-of-the-art and future trends in advanced rapid prototyping and
manufacturing, ”International Journal of Information Technology vol.1(2) pp.173–184.
[7]. Wheelwright, S.C. and Clark, K.B. (1992), Revolutionizing Product Development: Quantum Leaps in
Speed, Efficiency, and Quality, The Free Press, New York pp.21-24.
[8]. Ulrich, K.T. and Eppinger, S.D. (2000),Text Book “Product Design and Development”, 2nd edition,
McGraw Hill, Boston, pp.245-266.
[9]. Koren, Y. (1983), Text Book “Computer Control of Manufacturing Systems”, McGrawHill,
Singapore,pp.112-117.
[10]. Taraman, K. (1982), CAD/CAM: Meeting Today’s Productivity Challenge, Computer and Automated
Systems Association of SME, Michigan, vol.9, pp.23-25.

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GLOBAL TECHNICAL CAMPUS

4. WHY RAPID PROTOTYPING

THE DEVELOPMENT OF RAPID PROTOTYPING IS CLOSELY TIED IN WITH

The trends in manufacturing industries continue to emphasize the following:-

Rapid Prototyping improves product development by enabling better

LIQUID BASED RP SYSTEMS POWDER BASED RP SYSTEMS SOLID BASED RP SYSTEMS

1. SOLID GROUND CURING 1. SELECTIVE LASER SINTERING 1. LAMINATED OBJECT

NOTICE THAT THE FDM FILAMENT CANNOT CROSS ITSELF, AS THIS

2. ENGINEERING ANALYSIS AND PLANNING

3. TOOLING AND MANUFACTURING

 EARLY DESIGN FLAW DETECTION

 LIMITED VARIETY OF MATERIALS

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