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Rapid%20Prototyping

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Title: Rapid%20Prototyping


1
Rapid Prototyping
  • Prepared by
  • Zarith Zahran Bin Zaidi (57274113098)
  • Muhammad Jazli Jasri (57274113o42)
  • Muhammad Faez bin Othman (57274113066)
  • Nurul Fazlina binti Mohamad Zulfazlee(57274212089)

2
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.

3
Type of Rapid Prototyping
  • Stereolithography
  • Selective Laser Sintering
  • Laminated Object Manufacturing
  • Fused Deposition Modelling
  • Solid Ground Curing
  • Ink Jet printing techniques

4
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.

5
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.

6
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.

7
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.

8
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.

9
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.

10
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

11
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.

12
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.

13
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.

14
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

15
  • 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.

16
  • 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.

17
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.

18
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
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