What Is Rapid Prototyping

1.
What is Rapid Prototyping
Rapid Prototyping:
additive material
Traditional manufacturing:
subtractive material
1.1 Characteristics of RP
A technology that produces models and

prototype parts from 3D CAD model data, CT
and MRI scan data, and model data created from
3D object digitizing systems
RP systems join together liquid, powder and

sheet materials to form parts
Layer by layer, RP machines fabricate plastic,
wood, ceramic and metal objects
RP also known as Solid Freeform Fabrication (SFF)
or Layer Manufacturing (LM)
1.2 Basic process of RP

Three stages: pre-processing, building, and
post processing
CAD Model
Pre Process
RP Process
Post Process
Surface/Solid
Model
Generate
.STL file
Build
Prototype
Remove
Supports
in CAD
in RP
systems
Build Supports
if needed
Clean Surface
Post Cure if needed
Slicing
Part Completed
1.3 Benefits of RP
Shorten time to market &
reduced development cost
THE COST OF CHANGE
PHASE
COST
Conceptual modeling
Detail design
Prototype/test
Manufacturing
Product release
$10
$100
$1,000
$10,000
$100,000
Source: Wohlers Associates
Improved product quality

RP enable more design
iterations in a given time
3D visualization of product
designs
Esure that customers have a
clear understanding
A picture is worth a
thousand words; a model is
worth a thousand pictures.
2. Common types of RP
The
first RP system was introduced in 1988
Common
types of RP technologies now:
- StereoLithography (SL)
- Fused Deposition Modeling (FDM)
- Selective Laser Sintering (SLS)
- Laminated Object Manufacturing (LOM)
- 3D Printing (3DP)
2.1 Stereo-Lithography (SL)

Scanning
Mirror
Re-coating
Blade
Cured resin
to form model
Liquid Resin
Elevator & Platform
Laser
Supports
1. The elevator lowered by 1

layer deep;
2. The Blade sweep across
the vat, apply an even layer
of resin on top of the part;
3. As the laser beam strikes
the resin surface, the liquid
resin is hardened to a solid
plastic;
4. Loop through the three
steps to cure a new layer.
Stereo-Lithography Apparatus (SLA)

Representative:
from 3D Systems, Inc.
Materials:
photocurable resins
Adv. & Disadvantages:
Good dimensional
accuracy
Good surface finish
Narrow range of
materials
Relatively high cost
Post curing
Application areas:
- Prototypes for concept
models;
- Form-fit for assembly
tests and process
planning;
- Models for investment
casting, replacement of
the wax pattern;
- Patterns for metal
spraying, epoxy molding
and other soft tooling
2.2 Fused Deposition Modeling (FDM)

Model & Support Filaments
Part
Support
Heated extrusion
head
Elevator & Platform
1. Extrusion head and

elevator move to start
position;
2. The head extrude
layer of support;
3. The head extrude
layer of model;
4. Loop through the three
steps to build the next
layer.
Fused Deposition Modeling (FDM)
Representative:
from Stratasys Inc.
Materials:
thermoplastic material such as
wax, ABS plastic & elastomer
clean, simple, easy to operate

A good variety of material
Mid range performance/cost
Relative low accuracy
Poor strength in vertical
direction
- Slow for building a mass part
Application areas:
- Conceptual modeling;
- Fit, form and functional
test;
- Pattern for investment
casting;
- The MABS (methy
methacrylate ABS)
material is particularly
suitable for medical
applications.
2.3 Selective Laser Sintering (SLS)
Scanning
Mirror
Laser
Powder
cartridges
Piston
Support
Roller
Part
1. Piston of the part built

chamber lower by one layer;
2. Piston of powder cartridges
raise up;
3. Roller spread powder evenly
over the built surface;
4. Laser beam scan over the
top of the part, melting the
powder and fuse it to the
previous layer;
5. Loop through the four steps
to build the next layer.
Build
Chamber
Selective Laser Sintering (SLS)

Representative:
from DTM Corporation
Expensive running cost

Toxic gases generated
Application areas:
powder material such as nylon,
- Visual representation;
wax, polycarbonate, metal,
ceramic, elastomer, etc.
- durable enough for most
functional tests;
Large variety of material available
- Pattern for making soft
Produced in short time
tooling, casting;
No additional support required
- Direct manufacture of metal
No post curing required
mould;
Heat up powder & cool down part
Smoothness of surface restricted
- Small batch production run.
Materials:
2.4 Laminated Object Manufacturing

(LOM)
1. The sheet material is stretched
from the supply roller to the
take-up roller;
2. The heated laminated roller
passes over the sheet bonding
it to the previous layer;
3. Laser cuts the profile of that
layer and hatching the excess
material for later removal;
4. Loop through the three steps
to form a new layer.
Laminated Object Manufacturing (LOM)

Representative:
from Helisys
Materials:
sheet material such as paper,
plastic, ceramic, composite etc.

A relatively high speed process
No post curing required
No support structure required
Simple to use
The most commonly used
material is only paper
Must be post processed

immediately
Restricted to build complex
parts
Fire hazard occasionally
happened
Application areas:
- Visual representation;
- Concept modeling;
- Pattern for sand casting;
2.5 3D Printing (3DP)

Companies install them in offices
near their CAD systems for concept
modeling.
less costly and less capable

variation of RP technology
3. Application cases of RP
Common applications
of the RP technology:
Design
concept models
Marketing
models for tenders,
customer feedback,
presentations and
brochures
Test & Analysis
functional testing;
strong models for wind

tunnel and stress
analysis
Tooling
masters and patterns
for a broad range of
manufacturing processes
Medicine
artificial limbs, tools and
instruments
4. Rapid Tooling Making (RTM)
INDIRECT RPM: Pattern created by RP used to fabricate

tool
- RP-fabricated part as master in making silicon-rubber
mold (subsequently used as production mold)
- RP patterns to make sand molds for sand casting
- Fabrication of patterns of low-melting pt. materials for
Investment casting
DIRECT RPM: RP used to make the tool itself

- 3D printing to create die geometry in metallic powders
(followed by sintering & infiltration)
4. Rapid Tooling Making (RTM)
low volume (from

tens to hundreds)
- Soft Tooling
Intermediate (from
hundreds to
thousands)
- Metal filled Epoxy
Tooling
- Powdered Metal
Tooling
Aluminum-filled epoxy mold,

SL master, and molded
thermoplastic parts

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1.

What is Rapid Prototyping

A technology that produces models and

RP systems join together liquid, powder and

1.2 Basic process of RP

Source: Wohlers Associates

Improved product quality

first RP system was introduced in 1988

types of RP technologies now:

2.1 Stereo-Lithography (SL)

Elevator & Platform

1. The elevator lowered by 1

Stereo-Lithography Apparatus (SLA)

2.2 Fused Deposition Modeling (FDM)

Elevator & Platform

1. Extrusion head and

Fused Deposition Modeling (FDM)

Adv. & Disadvantages:

clean, simple, easy to operate

- Slow for building a mass part

2.3 Selective Laser Sintering (SLS)

1. Piston of the part built

Selective Laser Sintering (SLS)

Expensive running cost

2.4 Laminated Object Manufacturing

Laminated Object Manufacturing (LOM)

Adv. & Disadvantages:

Must be post processed

2.5 3D Printing (3DP)

less costly and less capable

strong models for wind

4. Rapid Tooling Making (RTM)

INDIRECT RPM: Pattern created by RP used to fabricate

DIRECT RPM: RP used to make the tool itself

4. Rapid Tooling Making (RTM)

low volume (from

Aluminum-filled epoxy mold,

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