EPP 331/4

Manufacturing Technology II
Lab Demo Report

Title : Rapid Prototyping

Group :5
Name : Lau Hieng Kiong
Matrix No. :102457
Lecturer : Pn. Ramdziah
Submission Date : 10 August 2010
Abstract

This report describes about the technologies associated with rapid prototyping, which share the
characteristics of computer integration, production without the use of traditional tools and dies
and the ability to rapidly produce a single part on demand. Rapid prototyping processes can be
classified into 3 categories, which is additive, subtractive and virtual. The rapid prototyping
machine introduced is FDM 3000 (Fused Deposition Modeling). Other than that, some problem
statements, objectives, methodologies, outcome and conclusion will be demonstrated too.
Lastly, some references regarding to the topic are attached along.

1.0 Introduction of RP(Rapid Prototyping) Machine

Rapid prototyping is the automatic construction of physical objects or example, which
shares the characteristics of computer integration, production without the use of traditional
tools and dies, and the ability to rapidly produce a single part on demand. [1], [2] In the
development of a new product, an example or prototype of a designed part or system
needed to undergo design evaluation and troubleshooting before the allocation of large
amounts of capital to new production facilities or assembly line. [1]

(b)

(a) (c)
Figure 1.1:
Rapid Prototyping Machine FDM3000 Figure 1.2(a), (b), (c):
Finish product from Rapid
Prototyping machine

1.1 Advantages of RP(Rapid Prototyping machine)

The advantages of RP technology include the following: [1], [3]

 Physical models of parts (in .STL format) produced from CAD data files can be
manufactured in a matter of hours and allow the rapid evaluation of manufacturability
and design effectiveness.
 Accelerate design iterations
 Test parts in actual production material
 Make the right tool-the first time
  Eliminate expensive and time-consuming tool modifications
 Reduce the total cost of tooling and production parts
 High work cycle

Figure 1.3:
Flow of a new component’s development
process, start from 3D solid model to
dependable production parts.

1.2 Rapid Prototyping Process

Rapid prototyping processes can be classified into three major groups: [1]
i. Subtractive
 Involve material removal from a workpiece that is larger than the final part.
ii. Additive
 Build up a part by adding material incrementally to produce the part, all
parts are build up in layers.
 Consist of stereo-lithography, fused deposition modeling, ballistic particle
manufacturing and etc.
iii. Virtual
 Use advanced computer based visualization technologies.

Figure 1.4:
Additive RP Process. (Slicing) Figure 1.5:
Additive RP Process
(Fused-deposition Modeling)
1.3 Introduction to FDM3000

Figure 1.1:
Rapid Prototyping Machine FDM3000

Models FDM 3000

Technology FDM
Build Size, mm(in) Parts up to 254x254x406 (10x10x16)
Accuracy, mm(in) ±0.127 (±0.005)
Layer road width, mm(in) 0.250 to 0.965 (0.010 to 0.038)
Layer thickness, mm(in) 0.178 to 0.356 (0.007 to 0.014)
Support structures Automatically generated with SupportWorks
software; WaterWorks or Break-Away Support
System(BASS)
Size, w x h x d, mm(in) 660 x 1067 x 914 (26 x 42 x 36)
Weight, kg(lbs) 160 (350)
Power requirements 208-240VAC, 50/60Hz, 10A
Modeling materials ABS(White), ABSi, Investment Casting Wax,
Elastomer
Support Materials Soluble P400SR
Software QuickSlice® and Support-Works™
Data Types .stl file
Table 1.1: Specification of FDM 3000 [4]

2.0 Problems Statement

1. It doesn’t has the sensor to monitor whatever the part is fabricated correctly, that’s
means if any corruption occurred, the machine will still continue extruding without
stopping.
2. No backup memory to store the running process. The machine cannot continue its
previous job when any long period blackout or low electric supply occurred that stop the
process.
3.0 Objectives

1. To learn Rapid Prototyping Operations.

2. To learn the principle of FDM.

4.0 Procedure / Methodology

1. CAD file description of the part is obtained.

2. Cad Drawing File is converted to .stl file before it is opened by using INSIGHT software.
3. By using the INSIGHT software, the STL file is manipulated its orientation and scale to fit
the modeling process.
4. Structure of the prototype is chosen, either in solid or sparse form.
5. Process started, base support for the prototype generated and constructed by injector.
6. First sliced layers created on the base. After that, the z-axis of the model is lowered for
the second sliced layer of ABS to be injected.
7. The process is repeated until the prototype is done.
8. Soluble base support is removed using WaterWorks which uses ultrasonic tank in a
water-based solution to remove the support material.

5.0 Outcome/ Conclusion

Process of FDM starts with a 3D CAD model sliced into thin layers in Z-axis. These sliced
layers are used to drive an extrusion head of FDM machine. The building material is in the
form of a thin solid filament, is fed from a spool to a movable head controlled by
servomotors. Second filament is fed from adjacent nozzle for support material, used to give
support for the prototype or model. The building materials then melted and then extruded
onto the part surface. After covering the whole cross section build by one layer thickness to
lay down the next layer. Process repeats itself until full 3D part is formed. The temperature
of machine chamber is precisely controlled below the melting point of the material so that
only little amount of heat is required to melt the filament and on the other hand part need
to be kept cool enough so that the molten material solidifies upon contact. FDM parts are
suitable for strong and functional testing exposed to temperature, water or chemicals.
These parts have almost 80% of the strength of injection moulded ABS material.

The principle of the FDM is based on surface chemistry, thermal energy, and layer
manufacturing technology. The material in spool form is melted in a head (injector), which
extrudes on the model. After it is extruded, the material is then cooled and solidified to form
the model or prototype. The model is built layer by layer. Parameters which will affect
performance and material column strength, viscosity, tip diameter, flow rate, temperature
and part geometry.
References

 Books
[1]. Serope Kalpakjian, “Manufacturing Engineering & Technology” 5 th edition, Prentice
Hall.

 Notes
[2]. http://en.wikipedia.org/wiki/Rapid_prototyping
[3]. www.fieldingmfg.com/rapid-prototyping.htm
[4]. http://www.creatingproducts.com/fdm3000.htm
[5]. www.arptech.com.au/fdmhelp.htm

 Electronic Media
Rapid prototyping: principles and applications By Chee Kai Chua, Kah Fai Leong, Chu Sing
Lim, http://books.google.com.my