Rapid-Prototyping Operations

Chapter 20
Rapid-Prototyping Operations
Manufacturing, Engineering & Technology, Fifth Edition, by Serope Kalpakjian and Steven R. Schmid.
ISBN 0-13-148965-8. 2006 Pearson Education, Inc., Upper Saddle River, NJ. All rights reserved.
Parts Made by Rapid-Prototyping
(c)
(a)
(b)
Figure 20.1 Examples of parts made by rapid-prototyping processes: (a) selection of

parts from fused-deposition modeling; (b) stereolithography model of cellular phone; and
(c) selection of parts form three-dimensional printing. Source: Courtesy of Stratasys, Inc.,
(b) and (c) Courtesy of 3D Systems, Inc.
Characteristics of Additive Rapid-Prototyping Technologies
Mechanical Properties of Selected Materials for Rapid

Prototyping
Computational
Steps in Rapid
Prototyping
Figure 20.2 The
computational steps in
producing a stereolithography
file. (a) Three-dimensional
description of each part. (b)
The part is divided into slices
(only one in 10 is shown). (c)
Support material is planned.
(d) A set of tool directions is
determined to manufacture
each slice. Also shown is the
extruder path at section A-A
from (c) for a fused-depositionmodeling operation.
Fused-Deposition-Modeling
Figure 20.3 (a) Schematic illustration of the fused-deposition-modeling process. (b) The
FDM 5000, a fused-deposition-modeling machine. Source: Courtesy of Stratysis, Inc.
Support Materials and Structures in Parts
Figure 20.4 (a) A part with a protruding section which requires support material.
(b) Common support structures used in rapid-prototyping machines. Source: P. F.
Jacobs, Rapid Prototyping & Manufacturing: Fundamentals of Stereolithography.
Society of Manufacturing Engineers, 1992.
Stereolithography
Figure 20.5 Schematic illustration of the stereolithography process.

Two-Button Computer Mouse
Figure 20.6 A two-button computer mouse.

Source: Courtesy of 3D Systems, Inc.
Selective-Laser-Sintering
Figure 20.7 Schematic illustration of the selective-laser-sintering process.

Source: After C. Deckard and P. F. McClure.
Three-Dimensional-Printing
Figure 20.8 Schematic illustration of the three-dimensional-printing process.

Source: After E. Sachs and M. Cima.
Three-Dimensional-Printing to Produce Metal Parts
Figure 20.9 Three-dimensional-printing using (a) part-build, (b) sinter, and (c) infiltration steps
to produce metal parts. (d) An example of a bronze-infiltrated stainless-steel part produced
through three-dimensional printing. Source: Courtesy of ProMetal.
Fuselage Fitting Made by Three-Dimensional-Printing
(a)
(b)
Figure 20.10 A fitting required for a helicopter fuselage. (a) CAD representation with added
dimensions. (b) Dies produced by three-dimensional printing. (c) Final forged workpiece.
Source: Courtesy of ProMetal.
Laminated-Object-Manufacturing
Figure 20.11 (a) Schematic illustration of the laminated-object-manufacturing

process. (b) Crankshaft-part examples made by LOM. Source: (a) Courtesy
of Helsis, Inc. (b) After L. Wood.
Invisalign Orthodontic
Aligners
(a)
(b)
Figure 20.12 (a) An aligner for orthodontic use manufactured using a combination of rapid
tooling and thermoforming. (b) Comparison of conventional orthodontic braces to the use
of transparent aligners. Source: Courtesy of Align Technologies, Inc.
Manufacturing of Invisalign
Orthodontic Aligners
(a)
(c)
(b)
Figure 20.13 The manufacturing sequence for Invisalign orthodontic aligners. (a) Creation of
a polymer impression of the patients teeth. (b) Computer modeling to produce CAD
representations of desired tooth profiles. (c) Production of incremental models of desired
tooth movement. An aligner is produced by thermoforming a transparent plastic sheet against
this model. Source: Courtesy of Align Technologies, Inc.
Investment Casting Using Rapid-Prototyped Wax Parts
Figure 20.14 Manufacturing steps for investment casting that uses rapid-prototyped wax
parts as blanks. This method uses a flask for the investment, but a shell method also can
be used. Source: Courtesy of 3D Systems, Inc.
Rapid Tooling for a Rear-Wiper Motor Cover
Figure 20.15 Rapid tooling for a rear-wiper motor cover.

Source: Courtesy of 3D Systems, Inc.

Rapid-Prototyping Operations

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Chapter 20

Parts Made by Rapid-Prototyping

Figure 20.1 Examples of parts made by rapid-prototyping processes: (a) selection of

Characteristics of Additive Rapid-Prototyping Technologies

Mechanical Properties of Selected Materials for Rapid

Support Materials and Structures in Parts

Figure 20.5 Schematic illustration of the stereolithography process.

Two-Button Computer Mouse

Figure 20.6 A two-button computer mouse.

Figure 20.7 Schematic illustration of the selective-laser-sintering process.

Figure 20.8 Schematic illustration of the three-dimensional-printing process.

Three-Dimensional-Printing to Produce Metal Parts

Fuselage Fitting Made by Three-Dimensional-Printing

Figure 20.11 (a) Schematic illustration of the laminated-object-manufacturing

Investment Casting Using Rapid-Prototyped Wax Parts

Rapid Tooling for a Rear-Wiper Motor Cover

Figure 20.15 Rapid tooling for a rear-wiper motor cover.

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