Rapid Prototyping- Non-Traditional Manufacturing Processes
- 1. Non-Traditional Manufacturing Processes P PT O N RAPID PROTOTYPING Submitted By- Saurabh Singh ASSIGNMENT-1
- 2. CONTENTS Rapid Prototyping Types of Prototypes in Product Design Rapid Prototyping and 3D printing Why Rapid prototyping Applications of Rapid prototyping Types Of PrototypingTechniques Advantages and DisadvantagesOf Rapid Prototyping Conclusion
- 3. Rapid Prototyping Rapid prototyping is the fast fabrication of a physical part, model or assembly using 3D computer aided design (CAD).The creation of the part, model or assembly is usually completed using additive manufacturing, or more commonly known as 3D printing. Where the design closely matches the proposed finished product it is said to be a high fidelity prototype, as opposed to a low fidelity prototype, where there is a marked difference between the prototype and the final product. The first methods for rapid prototyping became available in the late 1980s and were used to produce models and prototype parts. Today, they are used for a wide range of applications, and are used to manufacture production-quality parts in relatively small numbers if desired without the typical unfavorable short-run economics.
- 5. PROCESS OF RAPID PROTOTYPING
- 6. RAPID PROTOTYPING AND 3D PRINTING 3D printing and rapid prototyping are often confused as the same thing, however they are somewhat different. 3D printing is a method of additive manufacturing, whereas rapid prototyping is an application of this technology. 3D printing is a newer, more cost effective method of additive manufacturing. The original additive manufacturing process, stereolithography, was extraordinarily expensive and complex. Due to that cost and complexity, the only viable application was rapid prototyping. The quick turn around time of this process made it ideal for generating prototype parts. However, the high cost of the machines and the materials prevented significant market acceptance.
- 10. DIFFERENT TYPES OF RAPID PROTOTYPING Stereo-lithography (SLA) or Vat Photo- polymerization This fast and affordable technique was the first successful method of commercial 3D printing. It uses a bath of photosensitive liquid which is solidified layer-by-layer using a computer-controlled ultra violet (UV) light.
- 11. Selective Laser Sintering (SLS) Used for both metal and plastic prototyping, SLS uses a powder bed to build a prototype one at a time using a laser to heat and sinter the powdered material. However, the strength of the parts is not as good as with SLA, while the of the finished product is usually rough and may require secondary work to finish it.
- 12. Fused Deposition Modelling (FDM) or Material Jetting This inexpensive, easy-to-use process can be found in most non-industrial desktop 3D printers. It uses a spool of thermoplastic filament which is melted inside a printing nozzle barrel before the resulting liquid plastic is laid down layer-by-layer according to a computer deposition program. While the results generally had poor resolution and weak, this process is improving rapidly and is fast and cheap, making it ideal for product development.
- 13. Selective Laser Melting (SLM) or Powder Bed Fusion Often known as powder bed fusion, process is favoured for making high- strength,complex parts. Selective Laser Melting is frequently used by the aerospace, automotive, defence and medical industries. This powder bed based fusion process uses fine metal powder which is melted in a layer by layer manner to build either prototype or production parts using a high-powered laser or electron beam. Common SLM materials used in RP include titanium, aluminium, stainless steel and cobalt chrome alloys.
- 14. Laminated Object Manufacturing (LOM) or Sheet Lamination This inexpensive process is less sophisticated than SLM or SLS, but it does not require specially controlled conditions. LOM builds up a series of thin laminates that have been accurately cut with laser beams or another cutting device to create the CAD pattern design. Each layer is delivered and bonded on top of the previous one until the part is complete.
- 15. Digital Light Processing (DLP) Similar to SLA, this technique also uses polymerisation of resins which are cured using a more conventional light source than with SLA. While faster and cheaper than SLA, DLP often requires the use of support structures and post-build curing. An alternative version of this is Continuous Liquid Interface Production (CLIP), the part is continuously pulled from a vat, without the use of layers. As the part is pulled from the vat it crosses a light that alters its configuration to create the desired cross-sectional pattern on the plastic.