Rapid Prototyping

PREPARED BY : AKSHAY SHAH (160280708013)

L D COLLEGE OF ENGINEERING
SUBMITTED TO: PROF. B.C.KHATRI
Content Layout
• Introduction
• Types of Rapid Prototyping
• STL Format
Introduction
• Rapid Prototyping (RP) is a family of fabrication methods to make
engineering prototypes in minimum possible lead times based on a
computer-aided design (CAD) model of the item.
• RP technologies, a solid physical part can be created in a relatively short
time
• The designer can therefore visually examine and physically feel the part
and begin to perform tests and experiments to assess its merits and
shortcomings.
• RP allows a part to be made in hours or days, given that a computer
model of the part has been generated on a CAD system
Type of Rapid prototyping
Stereolithography
• This was the first material addition RP technology, dating from
about 1988 and introduced by3DSystems, Inc. based on the
work of inventor CharlesHull.
• (STL) is a process for fabricating a solid plastic part out of a
photosensitive liquid polymer using a directed laser beam to
solidify the polymer
• Part fabrication is accomplished as a series of layers, in which
one layer is added onto the previous layer to gradually build
the desired three dimensional geometry.
 Stereolithography Apparatus
• The stereolithography apparatus consists of

(1) a platform that can be moved vertically inside a vessel containing the photosensitive
polymer

(2) a laser whose beam can be controlled in the x-y direction.

• At the start of the process, the platform is positioned vertically near the surface of the liquid
photopolymer, and a laser beam is directed through a curing path that comprises an area
corresponding to the base (bottom layer) of the part.
Solid based Rapid prototyping process
• Starting material is a solid
• Solid-based RP systems include the following processes:
1. Laminated object manufacturing
2. Fused deposition modeling
Laminated Object Manufacturing (LOM)
• Solid physical model made by stacking layers
of sheet stock, each an outline of the cross-
sectional shape of a CAD model that is sliced
into layers
• Starting sheet stock includes paper, plastic,
cellulose, metals, or fiber-reinforced materials
• The sheet is usually supplied with adhesive
backing as rolls that are spooled between two
reels
• After cutting, excess material in the layer
remains in place to support the part during
building
Fused Deposition Modeling (FDM)
• 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 0.1 s
• Part is fabricated from the base up, using
a layer-by-layer procedure
Powder-Based RP Systems

• Starting material is a powder

• Powder-based RP systems include the following:

(1)Selective laser sintering

(2)Three dimensional printing

Selective Laser Sintering (SLS)
• Selective laser sintering (SLS) is a process based on the sintering of nonmetallic or
(less commonly) metallic powders selectively into an individual object.

• The bottom of the processing chamber is equipped with two cylinders:

(1) A powder-feed cylinder, which is raised incrementally to supply powder to the

part-build cylinder through a roller mechanism.

(2) A part-build cylinder, which is lowered incrementally as the part is being formed.

• First, a thin layer of powder is deposited in the part-build cylinder.

• Then a laser beam guided by a process-control computer using instructions

generated by the three-dimensional CAD program of the desired part is focused
on that layer, tracing and sintering a particular cross section into a solid mass.

• The powder in other areas remains loose, yet it supports the sintered portion.
Another layer of powder is then deposited; this cycle is repeated again and
again until the entire three-dimensional part has been produced.
SLS Layout
Three Dimensional Printing
• Part is built layer-by-layer using an ink-jet printer to eject adhesive
bonding material onto successive layers of powders
• Binder is deposited in areas corresponding to the cross sections of part, as
determined by slicing the CAD geometric model into layers
• The binder holds the powders together to form the solid part, while the
unbonded powders remain loose to be removed later
• To further strengthen the part, a sintering step can be applied to bond
the individual powders
Three Dimensional Printing

• Three dimensional printing:

(1) powder layer is deposited
(2) ink-jet printing of areas that will become the part
(3) piston is lowered for next layer
What is STL format?
• A STL file is a format used by Stereolithography
software to generate information needed to
produce 3D models on Stereolithography
machines. In fact, the extension "stl" is said to be
derived from the word "Stereolithography.“
• A slightly more specific definition of a stl file is a
triangular representation of a 3D object. The
surface of an object is broken into a logical series of
triangles (see illustration at right). Each triangle is
uniquely defined by its normal and three points
representing its vertices.
How to Create STL file
• Most CAD software packages offer stl conversion add-ins.
• If we have access to conversion software, stl translation is relatively simple
as long as you have a clean-surfaced 3D model and a high-end
computer.
• Traditionally when converting to a stl file, the user is given several options
for resolution (sometimes called chord height, triangle tolerance, etc.).
Depending upon the size of the model, the geometry of small details,
and the overall curvature of the part, the tolerance can typically be set
to 0.001 inch for average models.
• Small parts or models with fine details may require a tighter tolerance.