ENDG 105 Class 12.

RAPID PROTOTYPING
Creating Real Parts from Solid Models

Introduction
What is a Prototype?
A prototype is a draft version or an approximation of a final product. Prototypes are developed for several reasons: to identify possible problems that were not identified in previous stages of the design process. to confirm the suitability of a design prior to starting mass production. Provides a scale model to conduct tests and verify performance. for visualization purposes. Some prototypes are used as market research and promotional tools. Most importantly, it is cheaper to manufacture, test and make changes to a prototype than it is to a final product.

Rapid Prototyping
Rapid prototyping is a broad term that comprises many different technologies used to quickly fabricate a physical model directly from computer data. The first rapid prototyping method, called stereo lithography, was developed in the late 1980s, but more sophisticated techniques are available today.

Rapid Prototyping
The term rapid is relative. Some prototypes may take hours or even days to build (still much faster than the weeks that may be required for a technician to machine a design out of metal). Rapid prototyping systems are additive manufacturing processes that work on the basic principle of producing a 3D part by building and stacking multiple 2D layers together. Most common types of rapid prototyping systems: SLA (Stereo Lithography) SLS (Selective Laser Sintering) LOM (Laminate Object Manufacturing) FDM (Fused Deposition Modeling). Different technologies use different materials to produce the parts.

Stereo Lithography (SLA)

Uses a liquid photosensitive resin as building material and a low power laser to build the part one layer at a time. The 3D part is produced on a flat platform that is gradually submerged on a pool filled with photosensitive liquid resin.

For each layer, a laser beam traces out the corresponding crosssection pattern of the part on the surface of the liquid container.
The pattern is then solidified and added to the layer below. The platform descends one layer thickness (the layer thickness depends on the precision of the machine) and the process repeats. When the process finishes, the part is immersed in a chemical bath for cleaning and removing excess material

Stereo Lithography (SLA)

Stereo Lithography (SLA)

Selective Laser Sintering (SLS)

Uses a high power laser and powdered materials. A wide variety of materials can be used, ranging from thermoplastic polymers, such as nylon and polystyrene, to some metals.

3D parts are produced by fusing a thin slice of the powdered material onto the layers below it.
The surfaces of SLS prototypes are not as smooth as those produced by SLA processes. However, SLS parts are sufficiently strong and resistant for many functional tests.

Selective Laser Sintering (SLS)

The powdered material is kept on a delivery platform and supplied to the building area by a roller. For each layer, a laser traces the corresponding shape of the part on the surface of the building area, by heating the powder until it melts, fusing it with the layer below it. The platform containing the part lowers one layer thickness and the platform supplying the material elevates, providing more material to the system. The roller moves the new material to the building platform, leveling the surface, and the process repeats. Some SLS prototype machines use two delivery platforms, one on each side of the building platform, for efficiency, so the roller can supply material to the building platform in both directions.

Selective Laser Sintering (SLS)

Selective Laser Sintering (SLS)

Laminated Object Manufacturing (LOM)

Laminated Object Manufacturing is a relatively low cost rapid prototyping technology where thin slices of material (usually paper or wood) are successively glued together to form a 3D shape. The process uses two rollers to control the supply of paper with heatactivated glue to a building platform. When new paper is in position, it is flattened and added to the previously created layers using a heated roller. The shape of the new layer is traced and cut by a blade or a laser. When the layer is complete, the building platform descends and new paper is supplied. When the paper is in position, the platform moves back up so the new layer can be glued to the existing stack, and the process repeats.

Laminated Object Manufacturing (LOM)

Laminated Object Manufacturing (LOM)

Fused Deposition Modeling (FDM)

Involves melting a thermoplastic polymer (usually polyester, ABS plastic, or casting wax) and squeezing thin filaments out of a nozzle, layer by layer, on a building platform. As the material descends to the platform, it is immediately hardened. A second nozzle supplies soluble support material, if necessary, to the building platform to prevent certain geometry from deflecting because of gravity. When the process finishes, the FDM part is immersed in an alkali chemical bath to remove the support material. Depending on the machine, the nozzle can move across a stationary platform or the nozzle may remain stationary while the platform moves.

Although a slight layering texture is noticeable on the surface of the parts, plasticbased FDM machines produce very strong and durable prototypes that are ideal for functional testing.

Fused Deposition Modeling (FDM)

Fused Deposition Modeling (FDM)

Engineering Design Graphics Stratasys FDM Prototyper

Engineering Design Graphics Stratasys FDM Prototyper

Foundation Plate

Engineering Design Graphics Stratasys FDM Prototyper

Models after being build, but before cleaning.

Engineering Design Graphics Stratasys FDM Prototyper

Alkali (pH 11.5) bath before loading

Engineering Design Graphics Stratasys FDM Prototyper

Alkali (pH 11.5) bath

Engineering Design Graphics Old Thermojet Printer

Engineering Design Graphics Old Thermojet Printer

Stereo Lithography Files

The stereo lithography file format, known as STL (Standard Tessellation Language), is the current industry standard data interface for rapid prototyping and manufacturing. Before a 3D model is sent to a rapid prototype machine, it must be converted to this format. From a user standpoint, the process typically requires only exporting or saving the model as an STL file. Some software packages, however, allow the user to define some specific parameters. The STL file format defines the geometry of a model as a single mesh of triangles. Information about color, textures, materials, and other properties of the object are ignored in the STL file. When a solid model is converted into an STL file, all features are consolidated into one geometric figure. The resulting STL file does not allow individual features created with the parametric modeling application to be edited.

Inventor .stl Save Procedure

Remember to use Save Copy As not Save.

Select .stl as file type

Stereo Lithography Files

The process of approximating the actual surfaces of the object with a closed mesh of triangles is known as Tessellation.

When the tessellated STL file is sent to the rapid prototype machine, the model is sliced into multiple horizontal layers that are later reproduced physically by the device.

Working Drawings Project

Team Project (3 member teams) Today select you team exchange contact info. Project Design a unique custom themed portable barbeque pit Turn in a sheet of paper today with team name and members Next class turn in rough sketches of your different design considerations (multiple for each team), and a short memo discussing each design consideration (see handout).

Examples

Examples