RAPID PROTOTYPING, TOOLING AND MANUFACTURING

1 / 34
About This Presentation
Title:

RAPID PROTOTYPING, TOOLING AND MANUFACTURING

Description:

RAPID PROTOTYPING, TOOLING AND MANUFACTURING – PowerPoint PPT presentation

Number of Views:84
Avg rating:3.0/5.0
Slides: 35
Provided by: donaldl83

less

Transcript and Presenter's Notes

Title: RAPID PROTOTYPING, TOOLING AND MANUFACTURING


1
RAPID PROTOTYPING, TOOLING AND MANUFACTURING
  • Donald L. Kinser
  • Professor Mechanical and Materials Engineering
  • November 10, 2004
  • EECE-BME-ME-297 Design Seminar

2
WHAT IS RAPID PROTYPING?
  • Generic Term for ALL processes which generate
    prototypes quickly
  • Formative
  • Subtractive
  • Additive
  • Combinations or hybrid techniques
  • Google 11/2/04 rapid prototype produced 424,000
    results!

3
Rapid Prototype TechniquesFormative
  • Assembly of part by addition of components such
    as flat, channel, angle, rod, tube or other
    standard form available as a commodity
  • Joining may involve adhesives, welding, brazing,
    soldering or mechanical fastening

4
Rapid Prototype TechniquesSubtractive
  • Beginning with chunk of stock and removing
    portions through cutting operation
  • Rapid subtractive techniques include
  • Computer controlled machining
  • CNC computer numeric control or
  • NC numerical control

From Solid Concepts
5
Rapid Prototype TechniquesAdditive processes
  • Invention of Additive Process
  • Father of process Chuck Hall US Patent 1986
    Photopolymer based stereo lithography (3-D
    printing)
  • Commercialization of photopolymer based process
    begin in 1987
  • Rapid growth 495 million service bureau 2002
    with continuing rapid growth possibly 1 billion
    2004! (Wohlers Report 2002) (http//www.wohlersas
    sociates.com)
  • Alternative processes such as lamination,
    extrusion, sintering and jetting quickly
    developed

6
First additive process
  • Components
  • Laser 26
  • Platform 29
  • Motion control in X, Y and Z
  • Photopolymerizable liquid 23
  • Partially completed part 30
  • From Hull patent 4575330- 3/11/1986

7
Why Rapid Prototype?
  • Functional experimental model
  • Industrial design for look, feel,
  • Design of experiments-LAYOUT
  • Beta full scale functional with rough edges!
  • Preproduction
  • Tooling
  • Assembly
  • Verify performance
  • Financier, marketing, presale samples

8
Design of experiments-LAYOUT
9
Proof of conceptFunctional experimental model
10
Preproduction
11
Prototype USE?
  • Communication
  • Customers, suppliers, vendors, management,
    investors
  • Demonstration of project goals
  • Scheduling demonstration of milestones
  • Feasibility
  • Architectural interfacingfit, form, tolerance

12
Benefits of prototypes
  • Enhanced freedom and care in allocating
    resourcesidentify top priority design issues
  • Reduction of costly iterations
  • Acceleration of parallel activities
  • More flexible product choices
  • Pitfalls and distractions
  • Delay time to market through unnecessary
    prototype complexity or iteration
  • Failure to allocate time to integrate leads to
    inability to integrate prototype results into
    final product design

13
Additive prototype process 2004
  • Initial step assumes the existence of a 3-D CAD
    model of the part (2-D CAD design must be
    converted!)
  • CAD model is fed to a computer program which
    generates a solid model composed of triangular
    elements
  • Solid model is then converted to layered
    structure

14
Additive prototype process 2004
  • Physical Problems with element generation
  • Faceting
  • Stair stepping
  • Ovalization

15
2004 Additive Technologies
  • Stereo lithography
  • Selective laser sintering
  • Fused deposition modeling
  • 3-D printing
  • On the horizon
  • direct laser deposition of metals and ceramics
  • Direct build of parts for sale

16
Stereolithography
  • Most widely used permits creation of complex 3-D
    models by successive laser curing of liquid
    monomer resin

From Penn State learning factory
17
SLA Systems/Stereolithography.com
  • System capabilities (100-800K)
  • Beam (diameter _at_ 1/e2) Small spot 0.23 - 0.28 mm
    (0.009 - 0.011 in)
  • Large spot 0.685 - 0.838 mm (0.027 - 0.033 in)
  • Maximum part drawing speed Small spot 2.54 m/sec
    (140 ips)
  • Large spot 9.52 m/sec (525 ips)
  • Elevator
  • Vertical resolution 0.001 mm (0.00004 in)
  • Position repeatability 0.01 mm (0.0004 in)
  • Build Volume 508 x 508 x 584 mm
  • Maximum part weight 68 kg (150 lb)
  • www.3dsystems.com

18
Stereo lithography Parts
Compartmentalized bowl from Stereolithography.com
19
Stereo lithography Parts
Paintball gun model from Stereolithography.com
20
Selective laser sintering
Penn State learning factory
21
Z Corp Selective laser sintering25,900 system
  • Build Volume
  • 8 x 10 x 8 (203 x 254 x 203 mm) Layer
    Thickness
  • User selectable at time of printing .003-.010
    (.076-.254 mm)
  • Z Corp Selective Laser Sintering DEMO MOVIE

22
Selective laser sintering small parts
Z Corp carburetor body
23
Selective laser sintering complex parts
Z Corp housing
24
Selective laser sintering big parts
Z Corp Electrolux trim
25
Selective laser sintering aerodynamic flow model
Z Corp wind tunnel flow model
26
Medical Applications
  • Facilitating preoperative planning and rehearsal
    to optimize surgical technique
  • Ensuring superior implant design and body fit,
    reducing operative time and risk
  • Rapidly providing anatomically accurate skeletal
    models for surgeon evaluation
  • Refining available diagnostic information
  • Providing durable models that can be easily
    transported and sterilized for intraoperative use
  • Improving patient communications for informed
    consent of surgical procedures

27
Selective laser sintering surgical models
Z Corp skull section for surgery planning
28
Fused deposition modeling
Penn State learning factory
29
Fused deposition technology-little stuff
  • Stratasys
  • Stratasys FDM build movie (sales pitch)

Stratasys connector body
Stratasys small parts 0.005 inch detail
30
Fused deposition technology-big stuff
Stratasys differential cover
31
Fused deposition technology-big stuff
Stratasys monitor housing
32
Fused deposition technology-big stuff
Stratasys motorcycle cowling
33
Rapid Prototype Tooling
  • Prototyping of injection molds and dies employing
    sacrifice of prototype model pattern
  • Sand casting
  • Investment casting
  • Injection molding

34
Recent developments
  • Direct Manufacturing from Digital Parts Catalog
  • Laser deposition of metal or ceramic to fabricate
    final product
  • Other techniques to generate salable parts
  • Portable parts manufacturing strategies under
    consideration by NASA with US Army experimental
    deployment of parts factory
Write a Comment
User Comments (0)