Rapid Prototyping

Rapid Prototyping Systems
Department of Mechanical
Engineering

The term rapid prototyping (RP) refers to a
class of technologies that can automatically
construct physical models from ComputerAided Design (CAD) data.
These "three dimensional printers" allow
designers
to
quickly
create
tangible
prototypes of their designs, rather than just
two-dimensional pictures.

Of course, "rapid" is a relative term.
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.

Such models have numerous uses:
Excellent visual aids for communicating
Prototypes can be used for design testing.
Used to make tooling
Used to make production-quality parts

All RP techniques employ the same basic fivestep process.
1.
Create a CAD model of the design
2.
Convert the CAD model to STL format

(stereolithography)
3.
Slice the STL file into thin cross-sectional layers
4.
Construct the model one layer atop another
5.
Clean and finish the model

CAD Model Creation:
First, the object to be built is modeled using a
Computer-Aided Design (CAD) software package.
Solid modelers, such as Pro/ENGINEER, tend to
represent 3-D objects more accurately than wireframe modelers such as AutoCAD, and will
therefore yield better results.
This process is identical for all of the RP build
techniques.

Conversion to STL Format:
To establish consistency, the STL (stereo lithography,
the first RP technique) format has been adopted as
the standard of the rapid prototyping industry.
The second step, therefore, is to convert the CAD file
into STL format. This format represents a threedimensional surface as an assembly of planar
triangles.
STL files use planar elements, they cannot represent
curved surfaces exactly. Increasing the number of
triangles improves the approximation.

Slice the STL File:
In the third step, a pre-processing program
prepares the STL file to be built.
The pre-processing software slices the STL model
into a number of layers from 0.01 mm to 0.7 mm
thick, depending on the build technique.
The program may also generate an auxiliary
structure to support the model during the build.
Supports are useful for delicate features such as
overhangs, internal cavities, and thin-walled
sections.

Layer by Layer Construction:
The fourth step is the actual construction
of the part.
RP machines build one layer at a time from
polymers, paper, or powdered metal.
Most machines are fairly autonomous,
needing little human intervention.

Clean and Finish:
The final step is post-processing. This involves
removing the prototype from the machine and
detaching any supports.
Some photosensitive materials need to be fully
cured before use
Prototypes may also require minor cleaning and
surface treatment.
Sanding, sealing, and/or painting the model will
improve its appearance and durability.

Stereolithography
Patented in 1986, stereolithography
started
the
rapid
prototyping
revolution. The technique builds threedimensional
models
from
liquid
photosensitive polymers that solidify
when exposed to ultraviolet light.
The Stereolithography Machine
PT CAM uses a
stereolithography machine
produced by 3-D Systems and
shown here:
Picture of a statue using Stereolithography
Fused Deposition Modeling

(FDM) is a solid-based rapid prototyping method that
extrudes material, layer-by-layer, to build a model.
A thread of plastic is fed into an extrusion head, where it

is heated into a semi-liquid state and extruded through a
very small hole onto the previous layer of material.
Support material is also laid down in a similar manner.
Advantages of FDM Process
High strength
Cost-effective
Waterproof
ABS material
Multiple material colors
FDM 2000 Specifications

Build Volume: 10" x 10" x 10"
Materials:ABS, Casting Wax
Build Step Size: 0.005" to 0.030"
Prodigy Specifications
Build Volume: 8" x 8" x 10"
Materials: ABS, Casting Wax
Build Step Size: 0.007", 0.010", 0.013"
Up to 4x faster than the FDM 2000
Examples of
Laminated Object
Manufacture
As the name implies the process
laminates thin sheets of film (paper
or plastic)
The laser has only to cut/scan the
periphery of each layer
Laminated Object
Manufacture
The process:
The build material (paper with a thermo-setting
resin glue on its under side) is stretched from a
supply roller across an anvil or platform to a takeup roller on the other side.
A heated roller passes over the paper bonding it
to the platform or previous layer.
A laser, focused to penetrate through one
thickness of paper cuts the profile of that layer.
The excess paper around and inside the model is
Laminated Object
Manufacture
The process continued:
The process of gluing and cutting continuous
layer by layer until the model is complete.
To reduce the build time, double or even triple
layers are cut at one time which increases the
size of the steps on curved surfaces and the
post processing necessary to smooth those
surfaces.
Laminated Object
Manufacture
Applications of LOM objects:
LOM objects are durable, multilayered structures
which can be machined, sanded, polished, coated
and painted.
Used as precise patterns for secondary tooling
processes such as rubber moulding, sand casting
and direct investment casting.
Used for limited testing.
Used as visual models.
Laminated Object
Manufacture
Examples of Laminated Object

Manufacture
Wind Turbine
In this case the LOM
process was initially
used to check the CAD
geometry: subsequently
the model was used as
a sand casting pattern.
The picture opposite
shows
5
identical
blades
assembled
around an SLA hub.
Examples of Laminated Object

Manufacture
A LOM model was
built for a customer
who
required
a
prototype to test
the
fit
and
operation
of
internal
components in an
electrical housing.

Rapid Prototyping

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Rapid Prototyping Systems