Rapid Prototyping (RP)

What is Rapid Prototyping (RP)?

A family of fabrication processes to make

engineering prototypes in minimum lead time based
on a CAD model of the item
OR

Rapid Prototyping (RP) refers to a class of technologies

that can automatically construct physical model from
Computer Aided Design data

What is Rapid Prototyping ?

Rapid Prototyping (RP) allows a part to be made in
hours or days, given that computer model of the part
has been generated on a CAD system

Rapid Prototyping is being widely used in the

automotive, aerospace, medical and consumer
products industries

History of RP
Rapid prototyping is the automatic construction of
physical objects using additive manufacturing
technologies
The first techniques for rapid prototyping became
available in the late 1980s and were used to produce
models and prototype parts
Today, they are used for a much wider range of
applications and are even used to manufacture
production-quality parts in relatively small numbers

Why is Rapid Prototyping Important?

Product designers want to have a physical model of
a new part or product design rather than just a
computer model or line drawing
Creating a prototype is an integral step in design
process
A virtual prototype (a CAD model of the part) may
not be sufficient for the designer to visualize the part
adequately

Using RP to make the prototype, the designer can

see and feel the part and assess its merits and
shortcomings

Steps in RP
A 3-D representation of the object is created
using CAD software
A computer software program slices the 3-D
model into 2-D layers

A Process control software interprets the sliced

model to determine the appropriate processing
conditions for the deposition
The object is then built layer by layer

Illustration of RP Process

Typical RP process chain

CAD
3-D Modeling
STL file conversion

RP System
Computer

Slicing
RP Fabrication
Layer-by-layer
buildup

Post Processing
Cleaning
Finishing

3-D Physical Part

Example of Parts Made by RP

Examples of parts made by rapid-prototyping processes: (a) selection of parts
from fused-deposition modeling; (b) stereo lithography model of cellular phone;
and (c) selection of parts from three-dimensional printing.

Classification of RP Technologies
RP Technologies are generally classified
based on the form of the starting material
Liquid-based
Powder-based
Solid-based

Liquid-Based Rapid Prototyping Systems

Starting material is a liquid
About a dozen RP technologies are in this
category
Includes the following processes:
Stereolithography
Solid Ground Curing

Powder-Based RP Systems
Starting material is a powder
Powder-based RP systems include the
following:
Laser-Engineered Net Shaping (LENS)
Three Dimensional Printing

Laser Engineered Net Shaping (LENSTM)

Examples of Parts Created by LENS Process

Solid-Based Rapid Prototyping Systems

Starting material is a solid
Solid-based RP systems include the following
processes:
Fused deposition modeling
Laminated object manufacturing

Fused Deposition Modeling

Advantages of RP
RP allows Designers to make products faster and
less expensively

Rapidly Prototyped parts show great time, cost and

material savings
Quick product testing is possible
Expeditious design improvements

Fast error elimination from design

Advantages of RP (Continued)
Fast error elimination from design
Increased product sales
The speed of system development is increased
Rapid manufacturing is possible

Disadvantages of RP
Part accuracy:
Staircase appearance for a sloping part surface due
to layering
Shrinkage and distortion of RP parts
Limited variety of materials in RP:
Mechanical performance of the fabricated parts is
limited by the materials that must be used in the RP
process

RP Applications
Applications of rapid prototyping can be
classified into three categories:
Design

Engineering analysis and planning

Tooling and manufacturing

Laboratory Demo
on
Solid-Based Rapid Prototyping

The computational steps in producing a stereo lithography (STL) file. (a) Threedimensional description of part. (b) The part is divided into slices. (c) Support
material is planned. (d) A set of tool directions is determined to manufacture each
slice.

Fused Deposition Modeling (FDM)

Solid model or closed surface model required

Slicing the File

Series of closely spaced horizontal planes
are mathematically passed through the .stl
file
Generate a .stl file : a series of closely
spaced 2D cross-sections of the 3D object

Final Build File

Model part
Support part
RP technology parameters set
Send file to RP machine

Fabrication of Part

Model part built on platform.

Model and support shown attached to platform.

FDM Material

Post-processing
Removal of model from platform
Removal of supports from part
Cleaning of part
Finishing part (curing, sanding, polishing, )

THANK
YOU!