Prototyping

Why is it needed? Visualization and concept

To detect design flaws and verification tool.
necessary design Can sometimes be used in
improvements subsequent manufacturing
Chapter 19 Tooling operations
Rapid-Prototyping Operations Costs are high Tooling for manufacturing
Time consuming operations can be
produced
What is a first article?
First part that is Types of Rapid
Alexandra Schnning, Ph.D.
Mechanical Engineering manufactured for mass Prototyping
University of North Florida production. Subtractive Process
Figures by Why rapid prototyping? Additive Process
Manufacturing Engineering and Technology Virtual Process
Kalpakijan and Schmid Quick: CAD data files can
be manufactured in hours.
Some figures/text from: http://www.efunda.com/processes/rapid_prototyping/sgc.cfm
Easy: Will discover in lab!
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Rapid Prototyping Examples Subtractive Processes

(not necessarily what you normally consider rapid
prototyping)
Computer based drafting packages used to generate the
model
Interpretation Software
Translation of cad file to manufacturing software
CAD CAM
In I-deas you have both the CAD and the CAM component
Often you would use different software packages
Manufacturing Software
Machine operation planning
Will do this in a future lab: Manufacturing application in I-
Figure 19.1 (a) Examples of parts made
deas
by rapid prototyping processes. (b)
Stereolithography model of cellular
Computer Numerical Control Machinery
phone. CNC mill, lathe, machine center
We have the mill

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Additive Processes Rapid Prototyping Processes (Additive)

This is what most consider rapid prototyping Stereolithography
Parts are built in layers, slice by slice
Steps Fused deposition modeling
Create the geometry in a CAD software
Generate a file that can be imported into a slicing software (often *.stl)
Selective Laser Sintering
Use a slicing software to generate each of the slices
This software will generate the machine path
Solid Base Curing (Solid Ground Curing)
Send the sliced files to the rapid prototyping machine for manufacturing
(printing).
Ballistic particle manufacturing
Easy Three dimensional printing
Setup of computer file and initialization Ink-Jet printing
Fast
Additive processes are typically faster than subtractive processes Laminated-Object Manufacturing
Cleaning
Some of the additive processes require time consuming cleaning
procedures

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1
 Figure 19.2 The
computational
Stereolithography steps in
producing a
stereolithography
file. (a) Three-
Company: 3D Systems dimensional
Cures a liquid resin into the desired description of
shape part. (b) The part
The Process is divided into
slices (only one in
Sliced model is imported 10 is shown). (c)
A vat is filled with photocurable resin.
A platform, movable in the z-direction Stereo- Support material
is planned. (d) A
(up/down) sits in the vat
A laser moves in the x-y directions. lithography set of tool
directions is
The UV Beam cures the liquid resin on the determined to
plate into a solid layer. manufacture each
The plate is lowered so that a new thin slice. Shown is
layer can be cured. the extruder path
at section A-A
Support structure may be needed from (c), for a
Honey comb structure fused-deposition-
Machine Cost modeling
$100k $400k operation.
Tolerance
0.0125mm
Build size
0.5m x 0.5m x 0.5m

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Stereolithography Example of Stereolithography

Figure 19.6 A two-
Figure 19.5 Schematic button computer
illustration of the mouse.
stereolithography
process. Source: Ultra
Violet Products, Inc.

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Stereolithography (cont.) Stereolithography (cont.)

Circular Polariscope

Fringe Patterns
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2
 Fused Deposition Modeling
Fused Deposition Modeling
Company: Stratasys (a)
The machine we have is a Genesis Initial layer placed on a foam
Machine made by Stratasys foundation with a constant rate (a)
A robot controlled extruder head moves in (in the more advanced machines)
two principle directions (x and y) over a
table. Our version of the machine
The table can move up and down (z- prints the part directly onto
direction). the platform. It is therefore
Thermo plastic or wax filament is recommended to make small
extruded through the small heated orifice. feet to your part to aid in
easy removal
Extruder head follows a path
generated in the slicing software
One layer is built at a time. After
completion of each layer, the
table is lowered
Tolerance:
0.5- 0.25 mm (z direction)
0.025 mm in x- and y-directions

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Common Support Structures Selective Laser Sintering

SLS is a process based on A laser beam is focused on
sintering (to cause to the layer and sinters the
Figure 19.4 (a) A part with a protruding section which requires support material. (b) Common support become a coherent mass by powder
structures used in rapid-prototyping machines. Source: P.F. Jacobs, Rapid Prototyping &
Manufacturing: Fundamentals of Stereolithography. Society of Manufacturing Engineers, 1992.
heating without melting) of The non-sintered powder
non-metallic (sometimes remains loose and supports
metallic) powders into a the sintered portion.
desired shape. Company: 3D systems
Two cylinders
A powder feed cylinder
A part build cylinder
Powder feed cylinder is
raised incrementally to
supply powder to part-
build cylinder through a
roller mechanism
Part-build cylinder which
is lowered incrementally
to where the sintered part
is formed.

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Solid-Base Curing (Solid Ground Curing, SGC) Solid-Base Curing (Solid Ground Curing, SGC)

This process is different

from the previous in that
a complete layer at a time
is cured. High
production rates.
Expensive process.

Step 1: A CAD model

sliced into layers. At the
beginning of a layer
creation step, the flat
work surface is sprayed
with photosensitive resin:
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3
 Solid-Base Curing (Solid Ground Curing, SGC) Solid-Base Curing (Solid Ground Curing, SGC)

Step 2: For each layer, a Step 4: After the layer is

photomask is produced cured, uncured resin is
using Cubital's vacuumed for recycling
proprietary printing The cured layer is passed
beneath a strong linear UV
technique. lamp to fully cure it and to
Step 3: The photomask is solidify any remnant
positioned over the work particles.
surface and a powerful Step 5: wax replaces the
UV lamp hardens the cavities left by vacuuming the
exposed photosensitive liquid resin. The wax is
hardened by cooling to
resin: provide continuous, solid
support for the model as it is
fabricated. Extra supports are
not needed.

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Solid-Base Curing (Solid Ground Curing, SGC) Ballistic Particle Manufacturing

Step 6: The wax/resin Ballistic Particle Manufacturing
surface is milled flat to an Stream of material is ejected by
the use of an ink-jet style
accurate, reliable finish mechanism
for the next layer. 50m-droplets
Once all layers are 10,000 drops per second
completed, the wax is Three-dimensional Printing
removed, and any (3DP)
Print head deposits an inorganic
finishing operations such binder material
as sanding, etc. can be Binder directed onto a layer of
performed. No post-cure ceramic or metal powder
is necessary. A piston supporting the powder
bed is lower incrementally
Commonly used materials
Aluminum oxide, silicon
carbide,silica and zirconium.

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Ink-Jet Printing Laminated Object Manufacturing (LOM)

Company: ZCorp (others may exist) Layers of paper or plastic

One of the least expensive technologies
sheets with a heat
initially activated glue on one side
are stacked.
One of the least expensive technologies to
use Excess material is
Materials*: removed manually
Plaster-based The laser burns perforations
High strength requirements in a cross-sectional pattern
Delicate or thin-walled parts LOM uses sheets as thin as
Accurate representation of design details 0.05mm
Color printing
Composite-based Compressed paper has
Thin-walled enclosures appearance and strength of
Snap-fit applications soft wood , and often
Assembly applications mistaken for elaborate
The starch-based material is ideal for: wood carvings.
High speed printing
Large bulky parts
Inexpensive media
Patterns for investment casting
*http://www.zcorp.com/
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 Investment
Virtual Prototyping
Casting
Uses advanced graphics Rapid prototyped
software to examine parts parts can be used
Extremely good as the pattern in
rendering detail investment
Some design errors can casting.
be difficult to catch
Boeing 777 was created
without any physical
prototype.
Haptic (force feedback)
technology
You can feel virtual Figure 19.11 Manufacturing steps for investment casting that uses rapid--
prototyped wax parts as blanks. This approach uses a flask for the
objects. investment, but a shell method can also be used. Source: 3D Systems, Inc.
Company: Reachin
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Rapid Tooling Sand Casting Using Rapid-Prototyped Patterns

Rapid prototyping
can be used to
make the patterns
for sand casting
Advantage
Short time to
produce the
pattern
Disadvantage
Reduced pattern
life
Reduced
dimensional
tolerance
Wears with time
Some processes Figure 19.12 Manufacturing steps in sand casting that uses rapid-prototyped
patterns. Source: 3D Systems, Inc.
less accurate

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Sand Casting (continued)

Figure 19.12

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