1. Rapid Prototyping Designing for Rapid Prototyping © 2013 Project Lead The Way, Inc.Computer Integrated Manufacturing

2. Rapid prototyping devices are valuable in a design process –Prototype –Final product Understand RP equipment to improve a design Design for strengths and weaknesses of RP equipment Designing for Rapid Prototyping

3. Rapid Prototyping A virtual model is sliced into thin sections like a stack of playing cards Physical model is created one layer at a time from the base of the model Fused Deposition Modeling –A method of rapid prototyping which deposits heated thermoplastic layer by layer to create a physical model from a virtual model

4. Fused Deposition Modeling Subsequent layers need support from layer immediately below Support can be created –Support material from a second extruder –Low density pattern Support Material Removed

5. Fused Deposition Machine

7. Fused Deposition Materials Common thermoplastics –ABS, Acrylonitrile Butadiene Styrene –PLA, Polylactic Acid –PVA, Polyvinyl Alcohol

8. Fused Deposition Support Vertical features provide support for subsequent layers Part orientation can optimize support No Support Needed Support Needed

9. Fused Deposition Support Parts above void section often require support Support Geometry Low Density Pattern from Single Extruder

10. Fused Deposition Orientation Optimize and orient to minimize support Optimal Print Orientation Final Product Not Optimal Print Orientation

11. Fused Deposition Surface Finish Post processing can impact surface quality Orient model so finish is optimal Orientation for Production Inverted for Post-Production Processing Rough Unseen Side Finished Side To be Shown

12. Fused Deposition Infill Infill geometry of a solid model selected in printer software not.ipt or.stl Printing a ‘Solid’.stl Model

13. Designing for Rapid Prototyping ABS shrinkage –Design to compensate for shrinkage Part with a 0.069 in. Difference in Width Along a Dimension

14. Fused Deposition Parts Joining Parts can be joined using fasteners Rods Joining Parts Shrinkage Not Accounted for in Design

15. Fused Deposition Part Verification Verifying Accuracy Verifying Fit of Cams to VEX Shaft Verifying Fit of Adapter

16. References Groover M. P. (2012). Introduction to manufacturing processes. Hoboken, NJ: John Wiley & Sons, Inc.