SEMINAR ON RAPID

PROTOTYPING
Presented by:

Under the guidance of

Lecturer, Department of Mechanical Engineering

INTRODUCTION
The term rapid prototyping (RP) refers to a class of

technologies that can automatically construct physical

models from Computer-Aided Design (CAD) data.

These "three dimensional printers" allow designers to

quickly create tangible prototypes of their designs,

rather than just two-dimensional pictures.

Rapid Prototyping Replaced

Traditional Prototyping Techniques
Most prototypes require from three to seventy-two

hours to build, depending on the size and

complexity of the object.
This may seem slow, but it is much faster than the

weeks or months required to make a prototype by

traditional means such as machining.
These dramatic time savings allow manufacturers

to bring products to market faster and more

cheaply.

Historical
development
Year of Inception

Technology

1770

Mechanization

1946

First Computer

1952

First Numerical Control-(NC) Machine Tool

1960

First commercial Laser

1961

First commercial Robot

1963

First Interactive Graphics System

1988

First commercial Rapid Prototyping System

Steps in Rapid Prototyping process

Create a CAD model of the design

Convert the CAD model to STL format

Slice the STL file into thin cross-sectional

layers

Construct the model one layer atop

another

Clean and finish the model

Classification of RP Systems
RP techniques classified based on material
used in prototype or part is built with:
Solid based RP Systems.
Liquid based RP Systems.
Powder based RP Systems.

Solid Based RP Systems

Cubic Technologies Laminated object Manufacturing

(LOM)
Stratyasys Fused Deposition Modeling (FDM)
Kira Corporations paper Lamination Technology. (PLT)
3D systems Multi-Jet Modeling system. (MJM)
Solidscapes Model Maker and Pattern Maker, etc.

Liquid Based RP Systems

3D systems Stereolithography Apparatus (SLA)
Cubitals Solid Ground Curing (SGC)
Sonys Solid Creation system (SCS)
Rapid Freeze
Two Laser Beams
Microfabrication
Aaroflex., etc.,

Powder Based RP Systems

3D systems Selective laser sintering (SLS)
Z corporations Three Dimensional Printing (3DP)
Electron beam printing
Laser Engineered Net Shaping (LENS)
Direct Shell Production Casting.
Multiphase Jet Solidification. etc.,

Mostly Used RP Techniques

Stereolithography(SLA)
Selective laser sintering (SLS)
Fused Deposition Modeling(FDM)
Solid Ground Curing (SGC)
Laminated object Manufacturing(LOM)
Paper Lamination Technology(PLT)

Stereolithography(SLA)
Invented in 1986, stereolithography started the rapid prototyping
revolution. The technique builds three-dimensional models from
liquid photosensitive polymers that solidify when exposed to
ultraviolet light.

Principle
Parts are built from a photo-curable liquid resin that

cures when exposed to a laser beam (basically,

undergoing the photo polymerization process) which
scans across the surface of the resin.
The building is done layer by layer, each layer being
scanned by the optical scanning system and
controlled by an elevation mechanism which lowers
at the completion of each layer.

Stereolithography

Figure : Stereolithography: (1) at the start of the process, in which the initial
layer is added to the platform; and (2) after several layers have been added so
that the part geometry gradually takes form.

APPLICATIONS OF SLA
Models for conceptualization, packaging and presentation
Prototypes for design, analysis, verification and functional

testing
Parts for Prototyping tooling and low volume production

tooling.
Patterns for investment casting, sand casting and molding.
Tools for fixture and tooling design, and production tooling.

Parts Produced by Stereolithography

Picture of a statue using Stereolithography

A part produced by stereolithography (photo

courtesy of 3D Systems, Inc.).

Selective Laser Sintering

Moving laser beam sinters heat fusible powders in areas
corresponding to the CAD geometry model one layer at a time to
build the solid part
After each layer is completed, a new layer of loose powders is

spread across the surface

Layer by layer, the powders are gradually bonded by the laser beam

into a solid mass that forms the 3-D part geometry

In areas not sintered, the powders are loose and can be poured out

of completed part

Principle of sls
Parts are built by sintering when a CO 2 laser beam hits a thin

layer of powered material. The interaction of the laser beam

with the powder raises the temperature to the point of
melting, resulting in particle bonding, fasting the particles to
themselves and the previous layer to form a solid.
The building of the part is done layer by layer. Each layer of

the building process contains the cross sections of one or

many parts.

SELECTIVE LASER SINTERING

APPLICATIONS OF SLS
Concept models: Physical representations of designs used to review

design ideas, form and style.

Functional models and working prototypes: Parts that can withstand

limited functional testing, or fit and operate within an assembly.

Polycarbonate Patterns: Patterns produced using polycarbonate, then cast

in the metal of choice through the standard investment casting process.

Metal tools Direct rapid prototype of tools of molds for small or short

production runs.
Used to produce cavity and core inserts for injection molds.

Fused Deposition Modelling

RP process in which a long filament of wax or polymer is extruded
onto existing part surface from a workhead to complete each new
layer.
Workhead is controlled in the x-y plane during each layer and then

moves up by a distance equal to one layer in the z-direction

Extrudate is solidified and cold welded to the cooler part surface in

about 0.1s
Part is fabricated from the base up, using a layer-by-layer procedure.

Principle of FDM
The principle or the concept of the FDM is based on

surface

chemistry,

thermal

energy

and

layer

manufacturing technology.
The material is heated and then in controlled quantities

deposited directly on previous layers. Eventually layers

are built up to complete the entire part as shown in the
figure below

Fused Deposition Modelling

1 - Nozzle ejecting molten
plastic,
2 - Deposited material
(modeled part),
3 - Table

Working of FDM

Application of FDM
Models for conceptualization and presentation
Patterns and masters for tooling
Prototypes for design, analysis and functional testing

Prototypes Made by FDM

Advantages of RP
Direct Benefits
Benefits to Product Designers
Benefits to the Tooling and Manufacturing Engineer

Indirect Benefits
Benefits to Marketing
Benefits to the Consumer
DISADVANTAGES OF RP
Programming is difficult
Materials restriction

Applications of Rapid Prototyping

APPLICATIONS IN DESIGN
APPLICATIONS IN ENGINEERING, ANALYSIS AND PLANNING
APPLICATIONS IN RAPID TOOLING
AEROSPACE INDUSTRY
AUTOMOTIVE INDUSTRY
JEWELRY INDUSTRY
COIN INDUSTRY
TABLEWARE INDUSTRY
GEOGRAPHIC INFORMATION SYSTEM APPLICATIONS
ARTS AND ARCHITECTURE

CONCLUSIONS
Rapid prototyping will replace the modern machining

process in future
It requires minimum amount of time and there will be

less wastage
Complex parts can be easily produced
Rapid prototyping help to analyse the models

REFERENCES

T. Mueller, Applications of stereolithography in injection molding, Proc. Second Int. Conf. Rapid

Prototyping, 2326 June, Dayton, USA (1991), pp. 323329

J. H. Wang, C. S. Lim and J. H. Yeo, CFD investigations of steady flow in bi-leaflet heart valve,

Critical Rev. Biomed. Eng. 28(12), 6168 (2000).

3D Systems, The Winner: Ford Motor Company, 1994 Stereolithography Excellence Awards

(1995).

3D Systems, Stereolithography provides a symphony of benefits, The Edge 6(2), 67 (1995).

D. Atkinson, Rapid Prototyping and Tooling: A Practical Guide (Strategy Publications, U.K.,

1997).

Shonan Design Co. Ltd, Temp-Less 3.4.3UV RTV process for quick development and fast to

market (1996).

THANK YOU