Layered manufacturing and Rapid Prototyping

Rapid prototyping

The term 'Rapid prototyping' is normally used in the current today to specify a series of processors utilizing specialized equipment, software, and materials that are capable of using 3D CAD design data (as well as 3D scan data such as from a coordinate measuring machine ) to directly fabricate geometrical Complex objects.

Sometimes these processes are called additive processes since the material is added compared to the conventional processes of material removal that are generally used for prototyping.

 Rapid prototyping technologies are generally based upon a Layered manufacturing concept. In this method - a 3D model of the object as a CAD file is transferred into the system and then sliced into equidistant layers with parallel horizontal planes. The system then generates trajectories for the material to be added in each layer by the RP machine. Each physical layer from above is done deposited and fused to the previous layer using one of the many available depositions and Fusion Technologies.

Rapid prototyping is used to generate the product directly from the 3D CAD model data. A number of different processes such as stereolithography, selective laser sintering, 3D printing, fused deposition modelling, laminated object manufacturing, are used for this purpose.

There are a number of ways to 3D CAD design data can be represented. However, the STL (standard triangular language or stereolithography language) format is most common and is generally supported by all the RP equipment. Each physical layer from above is done deposited and fused to the previous layer using one of the many available depositions and Fusion Technologies.

History of Rapid prototyping

The first Rapid prototyping system was demonstrated at the 1987 AUTOFACT show in Detroit were used to produce prototypes utilizing the stereolithography process.

Advantages

• Product development time and the cost will be greatly reduced compared to the conventional prototyping techniques used.
•  By reducing the prototype development time, the total product design cycle will be shorter, thereby getting products to the market sooner.
•  Communications between marketing, engineering, manufacturing, and purchasing are enhanced due to the availability of physical prototypes.
• It is possible to have the physical model at critical design reviews thereby the decision-making process becomes more accurate.
•  In some cases, it is possible to perform functional prototype testing before committing to the actual tooling
•  By making available an accurate physical prototype, it is possible to generate precise production tooling.
•  Utilising it technology in metal casting for direct mode and core making from CAD files without the need of tooling drastically reduces lead time and cost of produced castings.

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 Read limitations of rapid prototyping and applications click here