Rapid Prototyping

(RP)
Compiled By:- Suwasit Dhiman
Lelogix Design Solutions Pvt. Ltd.
 What is RP?
 Automatic manufacturing of products using
additive manufacturing technologies.
 Takes virtual image from CAD software and
transform into thin, virtual and horizontal cross
section and creates thin layers.
 WYSIWYG process where the virtual model and
physical model are identical.
 Have the advantage of producing almost all type
of shape or geometric features.
RP Sequence
• CAD solid model
• ‘.STL’ file
• Slicing the file
• Final build file
• Fabrication of part
• Post processing
 CAD Solid Model
• Solid model or closed surface model required
 .STL File

• Standard data interface between the CAD

software and the machine.
• File consists of the X, Y, Z coordinates of the
three vertices of each surface triangle, with
an index to describe the orientation of the
surface normal.
• Smaller triangular facets produce high quality
of surface finish.
 Slicing the File
• Series of closely spaced horizontal planes
are mathematically passed through the .stl
file
• Generate a ‘.sli’ file : a series of closely
spaced 2D cross-sections of the 3D object
• Typical Z thickness 0.006” (0.150 mm)
Final Build File
Part

• Part sliced
Supports
• Supports sliced
• RP technology parameters set
• layer thickness, scan speed,...
• Send file to RP machine
 Fabrication of Part

Models built on stereolithography apparatus.

Part and supports shown attached to platform.
 Post-processing
• Removal of part from platform
• Removal of supports from part
• Cleaning of part (wiping, rinsing, ... )
• Finishing part (curing, sanding, polishing, … )
Rapid Prototyping Technologies
• Several technologies
Stereolithography (SL)
Laminated Object Manufacturing (LOM)
Selective Laser Sintering (SLS)
Fused Deposition Modeling (FDM)
Solid Ground Curing (SGC)
3D Printing (3DP)
Laser Engineered Net Shaping (LENS)
Stereolithography (SLA)
 Stereolithography (SLA)
• 3D Systems, Valencia, CA
• patent 1986, beginning of RP
• photopolymerization using UV laser
• epoxies, acrylates (brittle)
• excellent accuracy < 50 mm
• relatively slow
• $100000 to $500000.
 Process of SLA
 The process of SLA uses a vat of liquid UV-
curable photopolymer resin and a UV laser
to build parts. On each layer, the laser
beam traces a part cross-section pattern on
the surface of the liquid resin. Exposure to
the UV laser light cures, or, solidifies the
pattern traced on the resin and adheres it to
the layer below.
 Process of SLA
 After a pattern has been traced, the SLA's
elevator platform descends by a single
layer thickness, typically 0.05 mm to
0.15 mm (0.002" to 0.006"). Then, a resin-
filled blade sweeps across the part cross
section, re-coating it with fresh material.
 Advantages
 A functional part can be built within one day
and which becomes useful when working in
a “time is money” environment.
 Prototypes made by SLA can be used as
master patterns for injection molding, blow
molding etc.
Selective Laser Sintering (SLS)
• patent 1989, Carl Deckard’s master’s thesis
• fusing polymeric powders with CO2 laser.
• accuracy 160 mm.
• no supports.
• polycarbonate, nylon, wax, glass-filled nylon,
powder coated metals or ceramics.
• can be end-use parts.
 Process of SLS
 The process of Selective Laser Sintering is
actually quite simple. The entire internal system
is heated to below the melting point of whatever
substance is being used. So that when heat is
applied by the high energy CO2 laser melts and
fuses (sinters) the substance.
 Process of SLS
 To do this two piston-like platforms, a roller, an optical
sensor, and whatever material is being used to form a
part are used in co-ordination with the laser.
 The first piston contains most of the substance. When
this piston is raised it makes the substance available to
the roller. The roller moves the material over the second
piston to cover the part being constructed. The material
which has been moved to the second piston will then be
sintered by the laser, to form an additional layer on the
part.
 Other Features
 Price - Multiple pieces of the same part are much cheaper than
ordering a single piece. Even various SLS models ordered at the
same time as a single batch are much cheaper to make than
ordering separately.
 Speed - It could be few hours or a day it really depends upon the
build size, shape, and accuracy needed.
 Size of SLS single-made parts are generally 13.3” x 13.3” x 2’.
Although larger parts can be constructed by making many smaller
parts to assemble, and form a larger part. The thickness of an
individual SLS layer is 0.15 to 0.2 mm layer thickness, depending
upon the material used
 Advantages
 Compared to other technologies SLS can
produce parts from a relatively large variety
of powder materials.
 Unlike SLA, it does not require support
structures.
 Refrences
 Wikiepedia
 www.howstuffworks.com