Rapid Prototyping

Team Members 08MCD002D V SYAMALA GAYATRI 08MCD003HARIPRANEETH E 08MCD004HARSHA K 08MCD005 JAGADISHKUMAR R 08MCD008JEEVA P A 08MCD009KALLURI JAYA PRAKASH 08MCD010LOGESH M

Introduction Rapid Prototyping (RP) techniques are methods that allow designers to produce physical prototypes quickly. It consists of various manufacturing processes by which a solid physical model of part is made directly from 3D CAD model data without any special tooling. The first commercial rapid prototyping process was brought on the market in Nowadays, more than 30 different processes (not all commercialized) with high accuracy and a large choice of materials exist. These processes are classified in different ways: by materials used, by energy used, by lighting of photopolymers, or by typical application range. 08MCD005

Rapid Prototyping Technique Process Flow 3D Solid modeling Data preparation Part Building Redesign Pass Reject 08MCD005

Prototyping- What is it ?. Physical Model of the product. Degrees of Prototyping. Full Complete scale Model - functional model. Scaled Model - functional/ simulated material. Geometrical configuration 08MCD008

Prototyping- Why?  Visualization  Design Change  Complex Object Fabrication  Testing Fit/ Packaging  Cost, Time, and Resource estimation  Process Planning  First to Market -- Critical for today’s industry  JIT concept (0 Inventory)  Rapid tooling / no tooling -- trend in technology 08MCD008

Rapid Prototyping Processes  SLS --- Selective Laser Sintering  SLA --- Stereolithography  LOM --- Laminated Object Manufacturing  FDM --- Fused Deposition Modeling  Others 08MCD008

Rapid prototyping Processes- SLS Selective Laser Sintering 08MCD003

Application Range  Visual Representation models  Functional and tough prototypes  cast metal parts Advantages  Flexibility of materials used  No need to create a structure to support the part  Parts do not require any post curing except when ceramic is used. Disadvantages  During solidification, additional powder may be hardened at the border line.  The roughness is most visible when parts contain sloping (stepped) surfaces. Rapid prototyping Processes- SLS 08MCD009

Rapid prototyping Processes- SL Stereolithography 08MCD002

Application Range  Parts used for functional tests  Manufacturing of medical models  Form –fit functions for assembly tests Advantages  Possibility of manufacturing parts which are impossible to be produced conventionally in a single process  Can be fully atomized and no supervision is required.  High Resolution  No geometric limitations Disadvantages  Necessity to have a support structure  Require labor for post processing and cleaning Rapid prototyping Processes- SL 08MCD010

Other Processes Ballistic Particle Manufacturing (BPM) This process uses a 3D solid model data to direct streams of material at a target. 3D Printing It creates parts by layered printing process. The layers are produced by adding a layer of powder to the top of a piston and cylinder containing a powder bed and the part is being fabricated. Model Maker It uses ink jet printer technology with 2 heads. One deposits building material, and the other deposits supporting wax. Rapid prototyping Processes 08MCD004

Rapid Prototyping Products 08MCD004