07 Rapid Pro to Typing

8/3/2019 07 Rapid Pro to Typing

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Rapid Prototyping


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Rapid Prototyping

Layer by layer fabrication ofthree-dimensional physicalmodels from CAD

Fast and inexpensive alternativefor producing prototypes andfunctional models

Build parts in thin layers

Minimum operation time;typically runs unattended

Rapid Prototyping has

surgical applications
http://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.htmlhttp://www.engr.ncsu.edu/news/news_articles/harrysson.html


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Medical Modeling - Zcorp


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Rapid Prototyping Cycle

.STL (stereolithography) isstandard file format for allU.S. rapid prototypingsystems

Preprocessing prepares .STLfile for various rapidprototyping systems

Build process can last from a

few hours to several days Post processing: removal of

part from machine, supportremoval, sanding

Stereolithography (SL or SLA from Stereolithography Aparatus)

is an additive manufacturing technology for producing models,prototypes, patterns, and in some cases, production parts.


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Rapid Prototyping Process (Damvig)

A computer-controlled laser beam is

scanned across the surface of a vat of

liquid photopolymer, instantly

solidifying the liquid at each point of

contact. Using data generated from aCAD file, individual cross-sections of

the three-dimensional geometry are

solidified in turn to build up a solid

part layer by layer. In this way evenhighly complex geometries can be

built in a few hours without requiring

any tools.
http://www.damvig.com/english/index.htmhttp://www.damvig.com/english/index.htm


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Rapid Prototyping (RP)

Introduction of RP Generate a prototyping by Laying Manufacturing

Technology - composite material layer by layer

Build in one step - directly from model to

manufacturing


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Development of RP First Phase : Manual (or Hard) Prototyping

Age-old practice for many centuries

Prototyping as a skilled craft is traditional and manual

and based on material of prototype

Natural prototyping technique


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Development of RP Second Phase : Soft (or Virtual) Prototyping

Mid 1970s

Increasing complexity

Can be stressed, simulated and tested with exact

mechanical and other properties


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Development of RP Third Phase : Rapid Prototyping

Mid 1980s

Hard prototype made in a very short turnaround time

(relies on CAD modelling)

Prototype can be used for limited testing

prototype can consist in the manufacturing of the

products

3 times complex as soft prototyping


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Fundamentals of RP Building computer model

Model is building by CAD/CAM system

Model must be defined as enclosed volume or solid

Converting model into STL file format

STereoLithography (STL) file is a standard format to

describe CAD geometry used in RP system

STL file file approximates the surfaces of the modelby polygons


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Fundamentals of RP Fabricating the model

Building model layer by layer

Forming a 3D model by solidification of

liquid/powder


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Applications of RP For design evaluation

Touch and holding a physical prototype

For function verification

e.g. assembly, kinematics performance, and

aerodynamic performance

Models for further manufacturing processes

e.g. Vacuum casting, spray metal moulding,investment casting, etc.


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Advantages and DisadvantagesNo planning of process sequences

No specific equipment for handling materials

No transportation between machiningFeatures-based design and feature recognition

are unnecessary

Defining a blank geometry is unnecessary

Defining different setups or complex sequences

of handling material is unnecessary


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Advantages and DisadvantagesNo need to consider jigs and fixtures

Designing and manufacturing moulds and dies

Specific materials are restricted


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Role of RP in Product Development Cycle Product design

Increase part complexity and diversity with little

effect on lead time and cost

Minimise time-consuming discussion and evaluationsof manufacturing possibilities

Tool design and manufacturing

Minimise design, manufacturing and verification of

tooling

Reduce parts count and eliminate tool wear


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Role of RP in Product Development Cycle Assembly and test

Reduce labour content of manufacturing (e.g.

machining, casting, inspection and assembly, etc.)

Reduce material costs (e.g. handling, waste,transportation, spare and inventory, etc.)

Function testing

Avoid design misinterpretations, i.e. what you design

is what get)


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Due to the newness of the technology, thereare already so many words for RP used today:

RP( most commonly used) - Rapid Prototyping

RPTM(inc. new development trends) - Rapid

Prototyping, Tooling and Manufacture

Direct CAD Manufacturing/Desktop

Manufacturing/Instant Manufacturing/CAD

Oriented Manufacturing = RP

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