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Q.1 WHAT IS ADDITIVE MANUFACTURING
Rapid Prototyping (RP) is a term most commonly used to describe a variety of processes, which
are aimed at quickly creating three-dimensional physical parts from virtual 3D computer models
using automated machines .Rapid prototyping is different from traditional fabrication in that it is
only possible through the use of computers, both to generate the 3D CAD model data, as well as
to control the mechanical systems of the machines that build the parts. The parts are “built”
directly from the 3D CAD model and can match that model very closely.
This additive manufacturing process provides designers and engineers the capability to literally
print out their ideas in three dimensions. The RP processes provide a fast and inexpensive
alternative for producing prototypes and functional models as compared to the conventional
routes for part production.
The advantage of building a part in layers is that it allows you to build complex shapes that
would be virtually impossible to machine, in addition to the more simple designs. RP can build
intricate internal structures, parts inside of parts, and very thin-wall features just as easily as
building a simple cube.
RP process belong to the generative (or additive) production processes unlike subtractive or
forming processes such as lathing, milling, grinding or coining etc. in which form is shaped by
material removal or plastic deformation. In all commercial RP processes, the part is fabricated by
deposition of layers contoured in a (x-y) plane two dimensionally. The third dimension (z)
results from single layers being stacked up on top of each other, but not as a continuous z-
coordinate. Therefore, the prototypes are very exact on the x-y plane but have stair-stepping
effect in z-direction. If model is deposited with very fine layers, i.e., smaller z-stepping, model
looks like original. RP can be classified into two fundamental process steps namely generation of
mathematical layer information and 2 generation of physical layer model. Typical process chain
of various RP systems is shown in figure 1.
Figure 1: RP process chain showing fundamental process steps
It can be seen from figure 1 that process starts with 3D modeling of the product and then STL
file is exported by tessellating the geometric 3D model. In tessellation various surfaces of a CAD
model are piecewise approximated by a series of triangles and co-ordinate of vertices of triangles
and their surface normals are listed.
These STL files are checked for defects like flip triangles, missing facets, overlapping facets,
dangling edges or faces etc. and are repaired if found faulty. Defect free STL files are used as an
input to various slicing software. At this stage choice of part deposition orientation is the most
important factor as part building time, surface quality, amount of support structures, cost etc. are
influenced. Once part deposition orientation is decided and slice thickness is selected, tessellated
model is sliced and the generated data in standard data formats like SLC (stereolithography
contour) or CLI (common layer interface) is stored. This information is used to move to step 2,
i.e., generation of physical model. The software that operates RP systems generates laser-
scanning paths (in processes like stereolithography, Selective Laser Sintering etc.) or material
deposition paths (in processes like Fused Deposition Modeling). This step is different for
different processes and depends on the basic deposition principle used in RP machine.
Information computed here is used to deposit the part layer-by-layer on RP system platform.
The final step in the process chain is the post-processing task. At this stage, generally some
manual operations are necessary therefore skilled operator is required. In cleaning, excess
elements adhered with the part or support structures are removed. Sometimes the surface of
the model is finished by sanding, polishing or painting for better surface finish or aesthetic
appearance. Prototype is then tested or verified and suggested engineering changes are once
again incorporated during the solid modeling stage.
Q. 3 WHAT ARE THE AUTOMATED PROCESSES
In the subtractive process, one starts with a single block of solid material larger than the final
size of the desired object and material is removed until the desired shape is reached
In contrast, an additive process is the exact reverse in that the end product is much larger than the
material when it started. A material is
Manipulated so that successive portions of it combine to form the desired object.
Lastly, the formative process is one where mechanical forces or restricting forms are applied on a
material so as to form it into the
desired shape.
Subtractive
In the subtractive process, one starts with a single block of solid material larger than the final
size of the desired object and material is removed until the desired shape is
Reached
EXAMPLE
There are many examples for each of these fundamental fabrication processes. Subtractive
fabrication processes include most forms of machining processes — CNC or otherwise. These
include milling,turning, drilling,planning, sawing, grinding, EDM, laser cutting, water-jet cutting
and the likes.
Additive
In contrast, an additive process is the exact reverse in that the end product is much larger than the
material when it started. A material is manipulated so that successive portions of it combine to
form the desired object.
EXAMPLE:
Most forms of rapid prototyping processes such as Stereolithography and Selective Laser
Sintering fall into the additive fabrication processes category
Formative
Lastly, the formative process is one where mechanical forces or restricting forms are applied on a
material so as to form it into the desired shape.
EXAMPLE
Examples of formative fabrication processes are: Bending, forging, electromagnetic forming and
plastic injection
molding. These include both bending of sheet materials and molding of molten or curable
liquids. The examples given are not exhaustive but indicative of the range of processes.Hybrid
machines combining two or more fabrication processes are also possible. For example, in
progressive press working, it is common to see a hybrid of subtractive (as inblanking or
punching) and formative (as in bending and forming) processes.
DISADVANTAGES
MEDICINE
So much So much more is known about the human body than in the past, but the ability
to create tissue and organs has always been elusive. This ability to artificially
regenerate is something which is highly prized by medical scientists, having the
potential to cure or at least overcome the ravages of, disease, illness and injury
INDUSTRIAL USES
There’s a vast number of industries which have made use of the technology such as
aerospace, defence, industry and automotive, and each of these has found certain key
elements particularly beneficial. Tooling is used in all of these industries and has a
broad number of applications, and this is one area which can be significantly improved
with the use of additive manufacturing.
A10. The Better way is to classify Additive Manufacturing systems broadly by the initial form of
its material, all AM Systems can be easily
categorised into :
Liquid Based, Solid Based, Powder Based
LIQUID Based :
Stereolithography Apparatus(SLA), PolyJet 3D printing, Multijet Printing(MJP), Solid Object
Ultravoilet-Laser Printer(SOUP), Rapid Freeze Prototyping.
SOLID Based :
Fused deposition modeling (FDM), Selective Deposition Lamination (SDL), Laminated Object
Manufacturing (LOM), Ultrasonic Consolidation.
POWDER Based :
Selective Laser Sintering(SLS), ColorJet Printing(CJP), Laser Engineered Net Shaping (LENS),
Electron Beam Melting(EBM) etc.
Q11. List the different types of Liquid based RP systems?
A11. Most liquid-based rapid prototyping systems build parts in a vat of photo-curable liquid
resin, an organic resin that cures or solidifies under the effect of exposure to laser radiation,
usually in the UV range.The laser cures the resin near the surface, forming a hardened layer.
When a layer of the part is formed, it is lowered by an elevation control system to allow the next
layer of resin to be similarly formed over it. This continues until the entire part is completed.
A12. In Mechanical Engineering, the term Reverse Engineering (often abbreviated to RE) is used
to summarise the process of reconstructing an already existing object. In Reverse Engineering,
the design engineer starts with the final product and works through the design process in the
opposite direction to arrive at the product design specification.
The usual starting point of the process of Reverse Engineering is by gaining dimensional
information of the model, whether it is a mechanical component, a consumer product or an
ancient artefact. This is done with the use of a 3D scanner, such as Physical Digital's highly
accurate, GOM ATOS systems.
Q13. What are the three phases of prototyping? Contrasting these with those of geometric
modelling, what similarities can be drawn.