Rapid prototyping Higher product design

What is it? Method to producing 3D models or prototypes quickly, direct from 3D computer drawing Doesn’t use any of traditional model making tools Described as clean manufacturing Accurate and precise process Enables model maker to create intricate and complex forms.

Process

Process Model to be manufactured is built up a layer at a time. Layer of powder is automatically deposited in the model tray. Print head applies resin in the shape of the model. The layer dries solid almost immediately. The model tray then moves down the distance of a layer and another layer of power is deposited in position, in the model tray. The print head again applies resin in the shape of the model, binding it to the first layer. This sequence occurs one layer at a time until the model is complete

More Advantages 1. Complete 3D models can be manufactured including those with hollow parts that could not possibly be made by hand in one piece, even by the most skilled engineer or craftsperson. Parts such as bearings, engineering parts and complex working models can be manufactured. 2. A variety of resins and waxes can be applied to the completed model. These increase the strength of the model, its temperature resistance and allows paint and finishes to be applied realistically. 3. A two part urethane can be added to the model to give it the properties of rubber. 4. Models can be electroplated to give the look and feel of a range of metals. 5. Prototyping machines such as the ZPrinter 310 can even be used to produce highly accurate patterns for casting. 6. Manufactured model parts can be combined with real parts to produce a fully functioning product that can then be tested and evaluated.

Other methods of RP Selective laser sintering (SLS): Uses wider range of materials. Chosen material in powder form is rolled onto platform and a laser sinters selected areas. Fused deposition modelling (FDM): Coil of ABS is fed through heater, melted then extruded. Model is drawn one layer at a time by this molten filament. Each layer bonds to the one under it 3D printing (3DP): Uses materials in powder similar to SLS. Water based adhesive is printed using conventional ink-jet technology binding each layer together. Laminated object Manufacturing (LOM): Considered obsolete but still widely used in industry. Model built in layers using foil with an adhesive backing. Each layer is pressed to the next using heated roller and then cut by laser.