A PARADIGM SHIFT

Presented by

Himanshu Bharadwaj II yr Mechanical IIT Powai

Lara Sewlani II yr Mechanical IIT Powai

Evolution in India Recent cutting edge technologies Rapid prototyping Major rapid prototyping techniques Comparative view Applications Agile manufacturing Agile manufacturing + Rapid Prototyping Agile in electronics The paradigm shift Conclusion

1950-1960 : Initial phase of building the industrial foundation By 1990

By 2010

: liberalized sector
: 2nd largest global manufacturing hub

Rapid prototyping

High speed machining

Recent technologies
Automation & robotics nanotechnology

Assembly using three-dimensional computer aided design (CAD) Referred to as solid free-form or layered manufacturing
Manufacturing processes

Subtractive processes

Additive process

Shaping

Milling

Machining

Rapid prototyping

1.
2. 3. 4. 5.

To increase effective communication

To decrease development time. To decrease costly mistakes. To test the products. To create ideal models for tooling.

A CAD model is constructed. The material is processed by creating sliced layers of the model. 3. After each layer model is then lowered by the thickness of the previous layer. 4. After completion the model and any supports are removed. 5. Model is then finished and cleaned.
1. 2.

motor vehicle
consumer

5.5 8.2 8.6 8.8 11.2

7.7 31.7
business (construction) medical

18.4

academic aerospace govt. others

Major RP technique

SLS

SLA

FDM

3D Printing

GPD

Ink jet technique

Solid ground curing

LOM

BPM

SELECTIVE LASER SINTERING (SLS)

Production parts for unmanned aerial vehicles One piece fuel tanks Eliminates use of sub assemblies, adhesives or fasteners Health care & medical care application Investment casting process Gasket & facemask prototype

Industries where applied

Aerospace and military Automotives Direct digital manufacturing

Prototype manufacturing

Pattern masters for investment casting

Direct tooling for sand casting

Direct tooling for injection molding

Direct tooling for die casting

Artificial heart

STEREO LITHOGRAPHY (SLA)

Direct digital applications Medical & health care Hardware Tooling & pattern Investment casting patterns Jigs & fixtures Health care industries Automotive components & structures Military steel plants

Industries where applied

Jigs and fixtures

Spring prototype

Digital application

Home hardware

Military hardware

Human hand

FUSED DEPOSITION MODELLING (FDM)

Fit testing Functional testing, Rapid tooling patterns, Small detailed parts, Presentation models, Patient and food applications High heat applications
Health care industries Train , rail & car equipment industry Gas & oil production pipelines Pharmaceutical industry

Industries where applied:

Presentation model

Gas pipeline prototype

Fit & functional testing

Building prototype

Spinal cord prototype

Statue

SLS ADVANTAGES Manufacturing of complex geometries High mechanical and thermal resistance. Rapid delivery time Rubber like flexible parts can be made using elastomer Somos 201 Low density complex investment casting Suitable for seals, gaskets & high temperature app SLS parts have little rough & porous surface finish Surface finish is not as good and sharp as produced by SLA Plastic, metal and elastomeric powders with CO2 emission

SLA High dimensional accuracy Greatest accuracy with an excellent surface finish. Suitable for making master models for vacuum casting process Parts can be bead blasted, painted, textured finished, electroplated

FDM Office-friendly and quiet FDM is fast for small parts Strong and rigid parts makes them suitable for testing Dimensional stability is a key advantage At times products can be directly used as finished product parts High level of finish can be achieved

DISADVANTAGS

Parts are sensitive to Have a ribbed heat, moisture and appearance because of chemicals plastic is extruded in Not recommended for horizontal layers high humidity or could be a slower process temperature for very large parts Photopolymer resin with UV as emission laser Solid (Filaments), thermoplastics & elastomers and eutectoids

MATERIAL USED

LIMITATIONS

700 x 380 x 580mm3

508x 508x600mm

203 x 203 x 305mm

Focused on meeting the needs of customers while maintaining high standards of quality and controlling the overall costs involved
Why

is agile manufacturing an effective strategy?

Consumers love for gratification. Consumers love for choice. Consumers are fickle.

The goal of agile production manufacturing is to offer customized products at close to the price and speed of mass-production.
EXAMPLE. Earlier there used to be Fords one-size fits-all automobiles.

LEAN MANUFACTURING

AGILE MANUFACTURING

Leanness is eliminating wastes

Eliminating wastes as well as exploiting opportunities being flexible and nimble service levels and responsiveness for Agile manufacturing. Customer oriented production

Cost is the market winner for lean manufacturing Mass production as per order placed

Agile manufacturers are increasingly sophisticated CAD/CAM systems.

using

In addition, some manufacturers are turning to virtual reality to test their design concepts.
Example Caterpillar Inc., for instances using virtual reality to test drive huge earthmoving machines before they are built

The Product:
Conceptual validation: Esthetical, geometrical or dimensional Functional validation Mechanical, thermal or any physical solicitation validation Finished machining validation

The Realization mode:

Tooling validation Process validation Fabrication cadence validation

Improve reactivity fluctuations

with

respect

to

market

Help creativity and development of new concepts in design Simplify communication between customer and supplier Focused on configurability, modularity & upgradability of products and long-term satisfaction

Anticipate fabrication, maintenance, control or conditioning problems

Make rapid tests on the product to verify some of its characteristics (ergonomic, aerodynamic . .) Form a part which will be used as a pattern in order to make a tooling in a very short time. To address the customers' real needs they must sell solutions and not products.

Example: The great range, options and degree of customization offered by Dell computers have made it the current market leader.

Hondas new range of bikes come with an electronic key containing information that changes the performance of the machines according to the riders choice.

Liberalization increased foreign investments rapid strides in the field of hi-technology manufacturing of electronic products.

Problem with electronics manufacturing is the Constant change in technology to suit the trends and customer requirements.

OLD Product driven High product variety is bad Product replacement Functional orientation

NEW Customer driven High product variety is good Product upgrading Product orientation

Economies of sale
Dedicated equipments and jobs Single enterprise Information dynasties Top-down management

Economies of time
Agile equipments and jobs Network enterprise Open seamless information Vision-driven

SLS had the advantage to process wide range of material While Agile integrates an organization's people and technologies through innovative management RP is an area in which agile plays a key role in processes such as SLS,SLA& FDM Customers changing requirements are the demand while Agile + RP is the only supply satisfying them.

Mechanisms in Selective Laser Sintering and Selective Laser Melting, Prof. Dr. Ir. J.P. Kruth, Ir. P. Mercelis, et al., Dept. of Metallurgy and Materials Engineering, Reviewed, accepted August 4, 2004 (Pg.44-48). A Study of the STEREO LITHOGRAPHY Process, Deborah M. Cottrill, Univ. of WisconsinPlatteville, (Pg.1-6). PROCESSING and CHARACTERISATION of RAPID PROTOTYPING by Deniz Uzunsoy, Univ. of Birmingham, June 2003, (Pg.27-34). Rapid prototyping : principles and applications by Rafiq Noorani Journal of Materials Processing Technology 194 (2007) 8188 RAPID PROTOTYPING PROCESS SELECTION using graph theory and matrix approach by R. Venkata Raoa,, K.K. Padmanabhan The economic times articles on AGILE MANUFACTURING