Rapid Prototyping
A prototype is the first or original example of something that has or will be copied or developed. It is the model of preliminary version.
or
An approximation of a product or its components in some form for a definite purpose in its implementation.
Types of Prototypes• The implementation of the prototype: From the entire product itself or its subassemblies and components.
• The form of prototype: from a virtual prototype to a physical prototype.
• The degree of approximation of the prototype from very rough representation to exact replication of the product.
• Experimentation and learning
• Testing and proofing
• Communication and interaction
• Synthesis and integration and
• Scheduling and markets.
Roles of Prototypes
1770 Mechanization1946 First computer1952 First CNC machine tool1960 First commercial laser1961 First commercial robot1963 Fist interactive graphics system1988 First commercial Rapid prototyping system
Historical Developments
Three phases of development
First phase: Manual prototyping
Second phase: Soft or virtual prototyping
Third phase: Rapid prototyping
Fundamentals of Rapid Prototyping
• Input
• Material
• Method
• Application
RP wheel
Advantages of Rapid Prototyping
Direct Benefits
Benefit to Product Designer
Benefit to the Tooling and Manufacturing EngineerIndirect Benefits
Benefit to Marketing
Benefit to the Consumer
Disadvantages of Rapid Prototyping
• The price of machinery and materials are expensive.
• The surface is usually rougher than machined surfaces.
• Some materials are brittle.• The strength of RP-parts are weaker in z-
direction than in other.
Classification of Rapid Prototyping Systems
• Solid based
• Liquid based and
• Powder based system
The classification is done based on the type of material used for Prototyping.
Solid based RP systems
1. Fused Deposition Modeling (FDM) (Stratasys)2. Bench top system (Solids cape)3. Laminated Object Manufacturing (LOM) (Cubic
Technologies)4. Multi-jet Modeling system (MJM) (3D Systems)5. Paper Lamination Tech (PLT)(Kira) 6. CL 100 (CAM-LEM)7. Offset Fabbers (Ennex Corporation)8. Shape Deposition Manufacturing process
1. Stereo lithography Apparatus (3D systems)2. Polyjet (Objet Geometries Ltd.)3. Solid creation system (D-MEC)4. Perfactory (EnvisionTec)5. Solid Object Ultraviolet laser Printer (SOUP) (CMET)6. Bioplotter (EnvisionTec)7. Rapid freeze prototyping 8. ACCULAS (D-MEC)9. Two Laser Beams 10. Solid ground curing (SGC) (Cubital)11. Soliform system (Teijin Seiki)12. Rapid prototyping system (Meiko)
Liquid based RP systems
Powder based RP systems
1. Selective Laser Sintering (SLS) (3D system)2. Three Dimensional Printing (3DP) (Z Corporation)3. Laser Engineered Net Shaping (LENS) (Optomec)4. Electron Beam Melting (EBM) (Arcam)5. Selective Mask Sintering(SMS) (Sintermask Technologies )6. Micro Sintering (3D-Micromac)7. ProMetal (The Ex One Company)8. Direct Shell Production Casting (DSPC) (Soligen)9. Multiphase Jet Solidification (MJS) (Fraunhofer)10. Lasform Technology (Aeromet Corporation)
Fundamental Automated Process
Rapid Prototyping Process Chain
• 3D modeling• Data conversion and Transmission• Checking and preparing• Building• Post processing
Tessellation of 3D model
Slicing of 3D model
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