Rapid%20Prototyping

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Rapid Prototyping

• Prepared by
• Zarith Zahran Bin Zaidi (57274113098)
• Muhammad Jazli Jasri (57274113o42)
• Muhammad Faez bin Othman (57274113066)
• Nurul Fazlina binti Mohamad Zulfazlee(57274212089)

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What is Rapid Prototyping?

• a group of techniques used to quickly fabricate a
  scale model of a part or assembly using
  three-dimensional computer aided design (CAD)
  data.
• Construction of the part or assembly is usually
  done using 3D printing or "additive layer
  manufacturing" technology.
• Used in a wide range of industries, Rapid
  prototyping allows companies to turn innovative
  ideas into successful end products rapidly and
  efficiently.

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Type of Rapid Prototyping

• Stereolithography
• Selective Laser Sintering
• Laminated Object Manufacturing
• Fused Deposition Modelling
• Solid Ground Curing
• Ink Jet printing techniques

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Stereolithography

• Stereolithography (SLA), the first Rapid
  Prototyping process, was developed by 3D Systems
  of Valencia, California, USA, founded in 1986. A
  vat of photosensitive resin contains a
  vertically-moving platform. The part under
  construction is supported by the platform that
  moves downward by a layer thickness (typically
  about 0.1 mm / 0.004 inches) for each layer. A
  laser beam traces out the shape of each layer and
  hardens the photosensitive resin.

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Highlights of Stereolithography

• The first Rapid Prototyping technique and still
  the most widely used.
• Inexpensive compared to other techniques.
• Uses a light-sensitive liquid polymer.
• Requires post-curing since laser is not of high
  enough power to completely cure.
• Long-term curing can lead to warping.
• Parts are quite brittle and have a tacky surface.
• No milling step so accuracy in z can suffer.
• Support structures are typically required.
• Process is simple There are no milling or
  masking steps required.
• Uncured material can be toxic. Ventilation is a
  must.

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Selective Laser Sintering

• Selective Laser Sintering (SLS, registered
  trademark by DTM of Austin, Texas, USA) is a
  process that was patented in 1989 by Carl
  Deckard, a University of Texas graduate student.
  Its chief advantages over Stereolithography (SLA)
  revolve around material properties. Many varying
  materials are possible and these materials can
  approximate the properties of thermoplastics such
  as polycarbonate, nylon, or glass-filled nylon.

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Highlights of Selective Laser Sintering

• Patented in 1989.
• Considerably stronger than SLA sometimes
  structurally functional parts are possible.
• Laser beam selectively fuses powder materials
  nylon, elastomer, and soon metal
• Advantage over SLA Variety of materials and
  ability to approximate common engineering plastic
  materials.
• No milling step so accuracy in z can suffer.
• Process is simple There are no milling or
  masking steps required.
• Living hinges are possible with the
  thermoplastic-like materials.
• Powdery, porous surface unless sealant is used.
  Sealant also strengthens part.
• Uncured material is easily removed after a build
  by brushing or blowing it off.

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Laminated Object Manufacturing

• The figure below shows the general arrangement of
  a Laminated Object Manufacturing (LOM,
  registered trademark by Helisys of Torrance,
  California, USA) cell
• Material is usually a sheet laminated with
  adhesive on one side, but plastic and metal
  laminates are appearinpaper g.

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Highlights of Laminated Object Manufacturing

• Layers of glue-backed paper form the model.
• Low cost Raw material is readily available.
• Large parts Because there is no chemical
  reaction involved, parts can be made quite large.
• Accuracy in z is less than that for SLA and SLS.
  No milling step.
• Outside of model, cross-hatching removes material
• Models should be sealed in order to prohibit
  moisture.
• Before sealing, models have a wood-like texture.
• Not as prevalent as SLA and SLS.

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Fused Deposition Modelling

• Stratasys of Eden Prairie, MN makes Fused
  Deposition Modeling (FDM) machines. The FDM
  process was developed by Scott Crump in 1988. The
  fundamental process involves heating a filament
  of thermoplastic polymer and squeezing it out
  like toothpaste from a tube to form the RP
  layers. The machines range from fast concept
  modelers to slower, high-precision machines. The
  materials include polyester, ABS, elastomers, and
  investment casting wax. The overall arrangement
  is illustrated below

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Highlights of Fused Deposition Modelling

• Standard engineering thermoplastics, such as ABS,
  can be used to produce structurally functional
  models.
• Two build materials can be used, and latticework
  interiors are an option.
• Parts up to 600 600 500 mm (24 24 20
  inches) can be produced.
• Filament of heated thermoplastic polymer is
  squeezed out like toothpaste from a tube.
• Thermoplastic is cooled rapidly since the
  platform is maintained at a lower temperature.
• Milling step not included and layer deposition is
  sometimes non-uniform so "plane" can become
  skewed.
• Not as prevalent as SLA and SLS, but gaining
  ground because of the desirable material
  properties.

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Solid Ground Curing

• Solid Ground Curing, also known as the Solider
  Process, is a process that was invented and
  developed by Cubital Inc. of Israel. The SGC
  process uses photosensitive resin hardened in
  layers as with the Stereolithography (SLA)
  process. However, in contrast to SLA, the SGC
  process is considered a high-throughput
  production process.

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Highlights of Solid Ground Curing

• Large parts, 500 500 350 mm (20 20 14
  in), can be fabricated quickly.
• High speed allows production-like fabrication of
  many parts or large parts.
• Masks are created w/ laser printing-like process,
  then full layer exposed at once.
• No post-cure required.
• Milling step ensures flatness for subsequent
  layer
• Wax supports model no extra supports needed.
• Creates a lot of waste.
• Not as prevalent as SLA and SLS, but gaining
  ground because of the high throughput and large
  parts.

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Ink Jet Printing Techniques

• Ink jet printing comes from the printer and
  plotter industry where the technique involves
  shooting tiny droplets of ink on paper to produce
  graphic images. RP ink jet techniques utilize ink
  jet technology to shoot droplets of
  liquid-to-solid compound and form a layer of an
  RP model. Common ink jet printing techniques
• Sanders Model Maker
• Multi-Jet Modelling
• Z402 Ink Jet System
• Three-Dimensional Printing

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• Sanders Model Maker
• Exceptional accuracy allows use in the jewelery
  industry.
• Accuracy is partly enabled by a milling step
  after each layer deposition.
• Plotting system is a liquid-to-solid inkjet which
  dispenses both thermoplastic and wax materials.
• Compared to SLS and SLA, not as established.
• Multi-Jet Modelling
• Fast.
• Office-friendly non-toxic materials, small
  footprint, low odor.
• Simple operation operates as a network printer
  in an office environment.
• Models are primarily for appearance use.
• Compared to SLS and SLA, not as established.

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• Z402 Ink Jet System
• Fast one to two vertical inches per hour,
  depending on layer density.
• Office-friendly non-toxic materials, small
  footprint, low odor.
• Simple operation.
• Compared to SLA and SLS, not as established.
• Three-Dimensional Printing
• Binder is "printed" on unbound powder layer.
• Without milling step, work plane can become
  successively skewed.
• Not as established as SLA and SLS.

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Why Rapid Prototyping?

• To increase effective communication.
• To decrease development time.
• To decrease costly mistakes.
• To minimize sustaining engineering changes.
• To extend product lifetime by adding necessary
  features and eliminating redundant features early
  in the design.

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Benefits of Rapid Prototyping

• Fast and effective communication of design ideas
• Effective validation of design fit, form, and
  function
• Greater design flexibility, with the ability to
  run quickly through multiple design iterations
• Fewer production design flaws and better
  end-products