Rapid prototyping OVERVIEW

Prototype
Need of Rapid Prototype Rapid Prototype

Types of RP
Part Deposition Planning

Prototype
Uncertainty
Unexpected problems Introduction of prototype in product design process
Explore design alternatives Test theories Confirm performance

Need for Rapid Prototyping

Competitive market requirements Products in higher quality Short delivery time Reasonable costs Environmental concern Safety requirements

Evolution of Rapid Prototyping

Rapid Prototyping : Basic principle

Layer by layer material deposition i.e. additive process
Deposition of layers contoured in x-y plane Third dimension layers stacked up on top of each other

Process Chain

RP Process Workflow
Pre Process
RP process Post Process

Stereolithography
Photosensitive liquid resin, forms solid polymer, when

exposed to UV light.

Stereolithography

Stereolithography

Fine point support structure

Selective Laser Sintering

Polymeric powder is sintered, using modulated laser.

Fused Deposition Modelling

Movable nozzle (x-y), deposits thread of molten polymeric

material on substrate.

Laminated Object Manufacturing

Roll of material is cut, to required contour, deposited on

substrate using hot roller.

3D Printing
Ink-jet printing head injects liquid adhesive, to bind

powder material.

Applications

Part Deposition Planning

.stl input to RP software like QuickSlice, RPTools, etc.
Part deposition orientation Part accuracy Surface quality Building time Cost These are the factors influenced by part deposition orientation

Factors Influencing Accuracy

Errors due to tessellation Size of triangles Chordal Error- Distance between midpoint of any edge and original
nonlinear geometry.

Factors Influencing Accuracy

Errors due to slicing

Part Building
Curing Toughening or hardening of polymer material by

cross linking of polymer chains brought about by chemical additives, ultraviolet radiation, electron beam or heat.
Adjustment of chamber temperature and laser power.

Control Dimensional Calibration of systems Shrinkage

Part Finishing
Poor surface quality due to staircase effect Sand polishing Finishing technique selection Adaptive Slicing

Selection of Part Deposition Orientation

Reduces part building time
The selection is process specific Trade off between better surface quality and building time Genetic Algorithms To optimize surface quality, building time, maximum accuracy, cost.

Thank You !!!